0% found this document useful (0 votes)

243 views431 pages

Cad en

CAD Engineering

Uploaded by

bocevski

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

0% found this document useful (0 votes)

243 views431 pages

Cad en

CAD Engineering

Uploaded by

bocevski

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

You are on page 1/ 431

CAD BOOK

A projekt keretben elkszlt tananyagok:

Anyagtechnolgik
Materials technology
Anyagtudomny
ramlstechnikai gpek
CAD tanknyv
CAD book
CAD/CAM/CAE elektronikus pldatr
CAM tanknyv
Mrstechnika
Mrnki optimalizci
Engineering optimization
Vgeselem-analzis
Finite Element Method

Budapest University of Technology and Economics

Faculty of Mechanical Engineering
buda University
Dont Bnki Faculty of Mechanical and Safety Engineering
Szent Istvn University
Faculty of Mechanical Engineering

CAD BOOK
Course bulletin

Editor:

LSZL KTAI
Authors:

PTER HERVAY, RICHRD HORVTH,

LSZL KTAI, ISTVN MADARSZ,
BALZS MIK, LSZL MOLNR,
ISTVN NAGY, ISTVN OLDAL,
OLIVR PAPP, ATTILA PIROS,
LSZL RABB, ISTVN SZAB,
GEORGINA NRA TTH, KROLY VRADI
XY
XY
ANDRS
SZEKRNYES
2012

2012-2017, Lszl Molnr, Olivr Papp, Attila Piros, Lszl Rabb, Kroly Vradi,

Budapest University of Technology and Economics, Faculty of Mechanical Engineering;

Pter Hervay, Richrd Horvth, Balzs Mik, Georgina Nra Tth, buda University, Dont Bnki
Faculty of Mechanical and Safety Engineering;
Lszl Ktai, Istvn Madarsz, Istvn Nagy, Istvn Oldal, Istvn Szab, Szent Istvn University,
Faculty of Mechanical Engineering
READERS: Andrs Eled

Creative Commons NonCommercial-NoDerivs 3.0 (CC BY-NC-ND 3.0)

This work can be reproduced, circulated, published and performed for non-commercial purposes
without restriction by indicating the author's name, but it cannot be modified.

ISBN 978-963-685-7
PREPARED UNDER THE EDITORSHIP OF Typotex Publishing House
RESPONSIBLE MANAGER: Zsuzsa Votisky

GRANT:
Made within the framework of the project Nr. TMOP-4.1.2-08/2/A/KMR-2009-0029, entitled KMR
Gpszmrnki Karok informatikai htter anyagai s tartalmi kidolgozsai (KMR information science
materials and content elaborations of Faculties of Mechanical Engineering).

KEYWORDS:

computer aided design, CAD, virtual model, solid model, shape feature, parametrical modeling, sheet
metal parts, constraints, surface modeling, CAx systems
SUMMARY:

The activity of mechanical engineers has been changed during the last decade because the computer
became an integral part of the design process. The engineers can solve more complex tasks with
more effective and productive work. The aim of this coursebook is to overview the basis of computer
aided engineering activity. The certain chapters deal with 3D solid model building techniques through
the geometrical description till the features based parametric description. The material acquaints
with modeling of sheet metal parts and surface modeling as well. The assembly modeling describes
the various types of constraints and assembly operation procedures. An introduction to final
elements method gives chance to insight of CAD numerical techniques. The CAD Book is dedicated to
computer aided design, however all the CAx technology has a great importance for every engineering
activity.

Content
1. Introduction
CAD computer aided design Classification of CAD systems Areas of application
Process of new product creation Process of product development CAx technologies
Product development (VDI 2221.) Concurrent engineering Optimal product
Simulation Prototype CAD history Hardware
2. Geometric fundaments of CAD systems
Geometric elements Transformations Projection for display Display and shading
3. Geometric modelling
Introduction Manifold modelling systems Wireframe modelling Surface
modelling Mantle modelling Solid modelling
4. Feature-based geometric modelling
Features Component modelling
5. Attributive information and engineering calculations
Introduction Grouping attributive information Using file attributes Entering
customized information Extracting component-related information Intelligent
feature catalogue General features Design Library Creating library operations
Engineering calculations Manufacturers catalogues on the Internet Designers
Toolbox
6. Modelling of Sheet Metal Parts
Introduction, key notes Manufacturing based design Sheet metal features Flat
pattern calculation
7. Surface modelling
1. Mathematical base of the surface description 2. Applied surfaces in the practice of
the CAD 3. Typical surface-operation in the CAD systems
8. Engineering, assembly modelling
Definition of assembly History of the assembly methods Non geometric parameters
of the assembly Assembly geometric relationships Assembly kinematic
relationships Assembly other relationships Assembly structure Assembly
operations Assembly effects of model building Assembly effects to the design
9. Kinematical Analysis in CAD Environment
Introduction Main Topics: Basis of Mechanisms, 3D Modell Building for kinematical
analysis, Case study
10. Engineering drawing in CAD environment
Part description Modelling process CAD support 3D drawing Interactive
document Engineering drawing
11. CAD numerical Methods
Finite element method in engineering practice Finite element aided model of
production Equations used in FEM Equilibrium equations Geometric equations
Boundary conditions Boundary element method Kinematically admissible
displacement field Principle of Lagrange variation Statically admissible stress field
Elasticity problem Approximate displacement field

Lszl Ktai, SZIU

www.tankonyvtar.hu

CAD Book

12. Application of Finite Element Method

Beam with circular cross section Result comparison Modeling of thin-valled beams
Modeling of thin-valled open cross section beams Modeling of thick-walled
cylinders, tubes
13. Integration of CAx systems
13.1 CAx systems 13.2 Integration of CAx systems 13.3 Data exchange 13.4 CAD
libraries 13.5 Digital mock-up
14. PDM/PLM systems
Introduction PDM/PLM systems Concurrent engineering Product model and
information management Product Database Management (PDM) Product Lifecycle
Management (PLM)
15. Peripheral technologies
15.1 3D scanning 15.2 Rapid prototyping 15.3 CAM systems

www.tankonyvtar.hu

Lszl Ktai, SZIU

Budapest University of
Technology and Economics

Szent Istvn
University

buda University

Typotex
Publishers

TMOP-4.1.2-08/A/KMR-0029

CAD Book
1. Introduction
Author: Dr. Balzs Mik
miko.balazs@bgk.uni-obuda.hu

The evolution of the informatics has increasing influence in every field of the our life, so the
engineering is not mean exception. The work of engineers is changing, we can solve more
complex problems, but the different software tools ensure effective and productive work.
The CAD book presents the topic of computer aided design (CAD) in the viewpoint of
mechanical engineering, however the CAx technology has great importance in every
engineering field.

Balzs Mik, U

www.tankonyvtar.hu

CAD Book

CAD computer aided design

The CAD is the abriviation of Computer Aided Design, which means a wild range of computer
software tools, which support the design process. A CAD system can be a simple 2D drawing
system or a parametric associative hybrid modelling system.
The up-to-date method is this last concept, where
the parametric means the dimension driven modelling,
the associative means the live connection between the geometric elements,
the hybrid means the parallel and synergic surface and solid modelling.

www.tankonyvtar.hu

Balzs Mik, U

1. Introduction

Classification of CAD systems

Application area
Type of modelling
- 2D
- 3D

Type of objects
- wire frame
- surface
- solid
- hybrid

Parametrization
- Non-parametric
- Parametric

The CAD systems can be classified by several viewpoint.

The first is the application field. The CAD systems are developed in every industrial areas,
so we can find systems in the field of mechanical engineering, electric engineering,
architectural design, civil engineering, cloth and shoe design, medical application.
The type of the modelling can be 2D, when the representation of the part is similar to the
engineering drawing. The other method is the 3D modelling, when the model of the part
is build in the virtual space.
The applied modelling method can be wireframe modelling, when only the edges of the
part are defined. In case of surface modelling the CAD model is hollow, only the
boundary skin is defined. The solid modelling ensures realistic representation, the
model consists of simple elementary elements.
In case of parametric model, the size of the model is driven by the geometric parameters.
The size of a non-parametric model is defined by users modelling activity and the
dimensioning value is driven by the modelled object.

Balzs Mik, U

www.tankonyvtar.hu

CAD Book

Areas of application

Mechanical engineering
Electronic design
Architectural design
Civil engineering
Textile industry
Medical

The pictures shows the most important application of CAD systems. The CAD systems were
developed for these special application areas.
The typical application fields are:
Mechanical engineering
Electronic design
Architectural design
Civil engineering
Textile industry
Medical

www.tankonyvtar.hu

Balzs Mik, U

1. Introduction

Process of new product creation

New product creation

Create and purchase of

manufacturing equipments

Manufacturing process

Design of manufacturing
equipments
Product development

The new product creation process consists of four main step.

The first is the product development, when the full design documentation is produced
based on the market, customer and financial requirements.
The production needs manufacturing equipments, like tools, machine tools, moulds etc.
And if there are no exist, we have to design them. Then the manufacturing equipments
have to purchase or create, which sometimes need lot of time and it has a high cost.
The last stem is the production, which means part production and assembly.
As the figure shows, some sub-processes can be performed with overlapping in order to
reduce the lead time.

Balzs Mik, U

www.tankonyvtar.hu

CAD Book

Process of product
development

Creation of
product concept
Conceptional
design
Synthesis

Assessment

Detail design

Analysis

Documenting

The steps of the product development are the next in general case:
Creation of product concept. The function, engineering, quality, market and other
requirements are collected in order to define the aim of the development.
Conceptional design. The possible solution of each requirements are summarized.
Synthesis. Unite the separated elements.
Design assessment. The result is investigated in order to check, than it is suitable for the
initial requirements.
Detail design. The details of the product are designed.
Analysis of the design. The product design is complete for analysis and every of
important properties can be tested.
Documenting. The result of the design process is the full design documentation.

www.tankonyvtar.hu

Balzs Mik, U

1. Introduction

CAx technologies

CAD
CAM
CAE
CAPP
CAQA
CAPPS
CAST

The product development and production process is supported by computer software. The
name of this technology is CAx computer aided something. These software tools support
the specific engineering activities. The help of the computer means different things. In case
of manufacturing the CNC programs are generated by a CAM system, the CAE means the
collection of every engineering analysis and calculation. The task of the CAPP is to generate a
process plan for manufacturing. The CAQA is the programming of coordinate measurement
machines in general.
The most often used abbreviations are the next:
CAD computer aided design
CAM computer aided manufacturing
CAE computer aided engineering
CAPP computer aided process planning
CAQA computer aided quality assurance
CAPPS computer aided production planning and scheduling
CAST computer aided storage and transport

Balzs Mik, U

www.tankonyvtar.hu

CAD Book

Product development (VDI 2221.)

Idea

Requirements

Product
definition

Base funkction
of the product

Development

Conception

Scetching

Design

Calculation

Define aims

Preliminari and detail design

Variation

1 2 3 .. N

Testing

Assessment
and documenting

The picture shows the steps of the product development process based on VDI 2221.
recommendation.
The steps are similar as the previously mentioned process. The feedbacks and different
product variations and the testing and assessment process has a great role during the
product development. These activities characterise the lead time of the development.
The lead time will reduce if
We have a clear product concept in the early phase of the development.
The sub-processes can be performed parallel.
The information flow is good, every member of the development have actual and up-todate information.
Use CAx tool.
The motivation of the members are suitable.

www.tankonyvtar.hu

Balzs Mik, U

1. Introduction

Concurrent engineering

The steps of the product development were sequential, but in order to reduce lead time
some activities are performed parallel with overlapping. This method is the simultaneous or
concurrent engineering.
The application of the method needs
Clear design process,
High level collaboration between the members of the design team,
Application of CAx systems,
Common database.

Balzs Mik, U

www.tankonyvtar.hu

CAD Book

Optimal product
Production
Using
Recycling

The result of the development process is the product, which should be optimal solution of
the initial requirements.
A product is optimal if it is
suitable for production (material, manufacturing, assembly, inspection)
Suitable for using (working, operation, safety etc.)
Suitable for recycling.
During the inspections these viewpoints should be focused. The inspections and tests could
be performed on prototype, final part of a model.

www.tankonyvtar.hu

Balzs Mik, U

1. Introduction

Simulation
imitation of the behaviour of a system

The simulation is the imitation of the behaviour of a system.

The simulation has an important role during the engineering design. The main roles of the
product simulation:
assessment of design alternatives,
study the effect of the product to the environment,
study the performance of the product during the use of it,
investigation of the interaction between the product and the user.

Balzs Mik, U

www.tankonyvtar.hu

CAD Book

Prototype
Proof of concept Prototype
Form Study Prototype
User Experience Prototype
Visual Prototype
Functional Prototype

There is no general agreement on what constitutes a "prototype" and the word is often used
interchangeably with the word "model" which can cause confusion. In general, "prototypes"
fall into five basic categories:
A Proof of concept prototype is used to test some aspect of the intended design without
attempting to exactly simulate the visual appearance, choice of materials or intended
manufacturing process.
Form Study Prototype (Model) will allow designers to explore the basic size, look and feel of a
product without simulating the actual function or exact visual appearance of the product.
They can help assess ergonomic factors and provide insight into visual aspects of the
product's final form.
User Experience Prototype (Model).
A User Experience Model invites active human interaction and is primarily used to support
user focused research. While intentionally not addressing possible aesthetic treatments, this
type of model does more accurately represent the overall size, proportions, interfaces, and
articulation of a promising concept.
Visual Prototype (Model) will capture the intended design aesthetic and simulate the
appearance, color and surface textures of the intended product but will not actually embody
the function(s) of the final product. These models will be suitable for use in market research,
executive reviews and approval, packaging mock-ups, and photo shoots for sales literature.
www.tankonyvtar.hu

Balzs Mik, U

1. Introduction

Functional Prototype (Model) (also called a working prototype) will, to the greatest extent
practical, attempt to simulate the final design, aesthetics, materials and functionality of the
intended design. The functional prototype may be reduced in size (scaled down) in order to
reduce costs. The construction of a fully working full-scale prototype and the ultimate test of
concept, is the engineers' final check for design flaws and allows last-minute improvements
to be made before larger production runs are ordered.

Balzs Mik, U

www.tankonyvtar.hu

CAD Book

Prototype

Differences between a prototype and a production design in general, prototypes will differ
from the final production variant in three fundamental ways:
Materials: Production materials may require manufacturing processes involving higher
capital costs than what is practical for prototyping. Instead, engineers will attempt to
substitute materials with properties that simulate the intended final material.
Processes. Often expensive and time consuming unique tooling is required to fabricate a
custom design. Prototypes will often compromise by using more variable processes,
repeatable or controlled methods; substandard, inefficient, or substandard technology
sources; or insufficient testing for technology maturity.
Lower fidelity. Final production designs often require extensive effort to capture high volume
manufacturing detail. Such detail is generally unwarranted for prototypes as some
refinement to the design is to be expected. Often prototypes are built using very limited
engineering detail as compared to final production intent, which often uses statistical
process controls and rigorous testing.

www.tankonyvtar.hu

Balzs Mik, U

1. Introduction

CAD history
1960

1957 - Dr. Patrick J. Hanratty PRONTO (the

1st CAM system)
Early 1960s - Ivan Sutherland Sketchpad

1965 - Dr. Hanratty, General Motors - DAC

(Design Automated by Computer)
1966 - McDonnal-Dougles CADD
1967 Ford PDGS
1967 Lockheed CADAM

In the early 60s the first CAD systems appeared, the origins of the development were
automotive and aircraft industry. The 3D modelling mean wireframe modelling at this time.
The mathematical fundaments of computer aided geometry were researched, the
mathematical description of 3D curves and surfaces were created by de Casteljau and Bzier.

Balzs Mik, U

www.tankonyvtar.hu

CAD Book

CAD history
1970

Focus to the wide range of application

1975 - Avions Marcel Dassault CATIA

(Computer Aided Three Dimensional
Interactive Application)

1980

1980 DEC MicroVAX

1980 - IGES - Initial Graphic Exchange Standard

In the early 70s the development of the first CAD/CAM systems are closed and the industry
focused to the wide range of application. The serious automotive and aircraft companies
(Ford, General Motors, Mercedes-Benz, Toyota, Lockheed, McDonnell-Douglas) were the
primary users and developers, these companies develop special systems for in-house
application.
At 1975 the first 3D modelling CAD system was published by Avons Marcel Dassault. This
was the CATIA: Computer Aided Three Dimensional Interactive Application.
In 1980 the DEC MicroVAX was the first computer, which didnt required special aircondition and electric connection.
The standard IGES file format was the first step to the cooperation between CAD systems
and it started the integration and collaboration, which is the characteristic direction of the
todays developments.

www.tankonyvtar.hu

Balzs Mik, U

1. Introduction

CAD history
1980

1980 IBM PC
1981 Autodesk - AutoCAD Release 1
1982 - CADRA 2D CAD

1984 - Bentley Systems MicroStation

1984 - Diehl Graphsoft miniCAD
1985 - Micro-Control System CADKEY
1985 CATIA v2
1987 - Parametric Technology - Pro/Engineer
1990

1989 Unigraphics UniSolids

The real revolution in informatics started with the IBM PC, because the hardware became
cheaper and easy to use and work. The new generation of CAD systems utilised the
advantages of the PC-s. The AutoCAD became the leader system in this decade.
The Pro/Engineer introduced the model-tree, which shows the history of the modelling
process.

Balzs Mik, U

www.tankonyvtar.hu

CAD Book

CAD history
1990

1990 Boeing 777 full CAD design process

1990-94 - Autodesk AutoCAD

1 million licences / 4 years

1994 - Autodesk Mechanical Desktop 1.0

Commercial Rapid Prototyping Technologies

1995

In 1990 the Boeing 777 was the first project, which was performed by 3D CAD system. This
milestone proved the justification of existence of 3D CAD systems and generated a new
design process principles.
Rapid prototyping technologies appeared in the market, and the commercial systems
ensured the rapid production of the physical prototypes.

www.tankonyvtar.hu

Balzs Mik, U

1. Introduction

CAD history
1995

1995 - Intel Pentium Pro processor

1996 - Windows NT operation system
1997 OpenGL graphic card
1998 - Dassault System ENOVIA
PDM - Product Data Management

2000

1999 - Dassault System - CATIA v5

In the second half of this decade the PC technology was renewed:

The Intel Pentium Processor ensured the fast computing,

The Windows NT ensured the effective multitasking, and

The OpenGL technology ensured the fast computing of the 3D graphics.

The new trend in the integration was the PDM Product Data Management, which extended
the limits of the collaboration .

Balzs Mik, U

www.tankonyvtar.hu

CAD Book

CAD history
2000

3D scanning
Reverse engineering
Wild range of simulations
Digital mock-up
Photorealistic image
Product Lifecycle Management

2010

Dassault Systemes CATIA v5 & ENOVIA

Siemens NX & iMAN
PTC - Pro/Engineer & WindChill

The prime mover of the development was the fast revolution of the PC hardware in the new
century.
The main keywords of this decade are:

3D scanning and Reverse engineering: digital reproduction of the real parts

Digital mock-up: digital prototype with wild range of simulations

Photorealistic image

Product Lifecycle Management: extended collaboration

The leader integrated CAD systems are

The Dassault Systemess CATIA v5 & ENOVIA

The Siemenss NX & iMAN

The PTCs Pro/Engineer & WindChill

www.tankonyvtar.hu

Balzs Mik, U

1. Introduction

Hardware

Special devices for CAD applications

The evolution of the hardware can be presented by two examples:

The IBM 7094 type computer (1970) needed special environment, many operator for
maintenance, and large space. Nowadays a commercial laptop is able to serve CAD
systems.

In 1980 an IBM 3380 hard disk was 2.000 kg, the price was 800.000,- $, and the capacity
was 20GB. In 2010. a microSD card is 1 g, the price is less than 100,- $, and the capacity is
32GB.

There are several special device for more effective use of CAD systems, like virtual reality
helmet, special mouse and interactive modelling devices.

Balzs Mik, U

www.tankonyvtar.hu

Budapest University of
Technology and Economics

Szent Istvn
University

buda University

Typotex
Publishers

TMOP-4.1.2-08/A/KMR-0029

CAD Book
2. Geometric fundaments of CAD systems
Authors: Dr. Balzs Mik
Pter Hervay
Georgina Nra Tth

www.tankonyvtar.hu

miko.balazs@bgk.uni-obuda.hu
hervay.peter@bgk.uni-obuda.hu
toth.georgina@bgk.uni-obuda.hu

Balzs Mik, Pter Hervay, Georgina Nra Tth, U

2. Geometric fundaments of CAD systems

GEOMETRIC ELEMENTS

Balzs Mik, Pter Hervay, Georgina Nra Tth, U

www.tankonyvtar.hu

CAD Book

Point
z
r

P(x,y,z)

x1
r x1 i x2 j x3 k x2
x3

In a CAD system in the 3D virtual space the geometric elements are represented in a
Descartian coordinate system by x, y, and z values.
The simplest geometric element is the point, which is used as datum elements in a CAD
modelling. The representation of a point is done by the 3 coordinate value.

www.tankonyvtar.hu

Balzs Mik, Pter Hervay, Georgina Nra Tth, U

2. Geometric fundaments of CAD systems

Curves
x=x(t)
y=y(t)

Explicit definition:

Implicit definition:

f(x,y)=0

t 0,1

Example: CIRCLE

x xo R cos 2t
y yo R sin 2t

xo,yo

t 0,1

x xo 2 y yo 2 R 2 0
Y

A curve is a continuous set of points. A curve can be defined by explicit or implicit definition.
The explicit formula is suitable for generating the points of the curve, and the implicit
formula is suitable for investigating a location of a point. If the value of the formula is 0, the
given point is the part of the curve.
In the CAD practice the explicit definition is applied.
The example shows the definition of a circle. The radii of the circle is R and the centre point is
xo, yo.

Balzs Mik, Pter Hervay, Georgina Nra Tth, U

www.tankonyvtar.hu

CAD Book

3D curves
Explicite definition:

Example: LINE

General description by polinoms:

x=x(t)
y=y(t)
z=z(t)

x(t ) ai t i
i 0
n

y (t ) bi t i
i 0
n

ci t i
i 0
t 0,1
z (t )

z2
z1
x2

x x1 t x2 (1 t )
y y1 t y2 (1 t )

z z1 t z2 (1 t )
t 0,1

y1
x1

The 3 D curves can be defined by explicit formula. The example shows the definition of a line,
which go through (x1,y1,z1) and (x2,y2,z2) points.
The classic curves, like line, circle, ellipse etc.) have explicit definition, but a general curve
hasnt got a description. These curves can be defined by polynoms, which are adjusted by ai,
bi, ci factors. The polynoms can be differentiated continuously, which is essential for many
investigation.

www.tankonyvtar.hu

Balzs Mik, Pter Hervay, Georgina Nra Tth, U

2. Geometric fundaments of CAD systems

Complex curves
Interpolation

Approximation

The set of factors are not so easy, therefore we use control points in the CAD environment in
order to define a curve. We can speak about interpolation, if the curve goes through these
points, or approximation, if the curve draws near to these points. Both of these methods are
used in theoretic mathematic description and in CAD systems.
A complex curve can be defined by many points. We can use two strategy:
Use a high degree polynom, or
Multisegment low degree polynoms.
The high degree polynoms sometimes become wave, therefore we prefer the second way of
curve design. The connecting segments have to be continuous, and the continuity has
different aspects.

Balzs Mik, Pter Hervay, Georgina Nra Tth, U

www.tankonyvtar.hu

CAD Book

Lagrange interpolation

n 1

r (t j ) x(t j ), y (t j ) ai , bi t ij rj
i 0

n 1

r (t ) Li (t ) ri
i 0

(t t )
L (t )
(t t )
j

j i

In case of Lagrange interpolation the control points are r1, r2, rn. We found the minimum
degree L(t) polynom, which gives r1, r2, rn points in t1, t2, tn. The number of degree of the
polynom will be (n-1), and the required [ai,bi] factors can be calculated from the equation
system, which gives from the j=1, 2, n points. The result is the Li(t) weight function.
In case of modification of one point, it has an influence to the whole polynom and this is the
main disadvantage of the Lagrange interpolation polynom.

www.tankonyvtar.hu

Balzs Mik, Pter Hervay, Georgina Nra Tth, U

2. Geometric fundaments of CAD systems

Bzier interpolation
(1)

n
n
(t (1 t )) n t i (1 t ) ni
i 0 1

n
Bi( n ) (t ) t i (1 t ) ni
i

3
i

(2) b(t ) b i t i (1 t ) 3i
i 0

b(t ) b 0 (1 t ) 3 3 b1 t (1 t ) 2 3 b 2 t 2 (1 t ) b3t 3
b(t ) b o (t 3 3 t 2 3 t 1) b1 (3 t 3 6 t 2 3t ) b2 (3 t 3 3 t 2 ) b3t 3

The Bzier interpolation polynome is the most known polynom, which was created in 1972
for the CAD applications.
It uses control points:
The curve will go through the outside points (po and pn),
The tangent vector in the outside points are p1-p0 and pn-1-pn.

The weight function should be symmetric, so the curve will be same if the order of the
points will be changed.
The Bernstein polynome (1) is one of the result of this problem.
In case on n=3 Bzier curve needs four control points, the curve go through in 1st and 4th
points, and draws neat 2nd and 3rd.
The cubic Bzier curve is the (2).
The tangent vectors in the start and finish points are:
b(0) = 3 (b1-b0)
b(1) = 3 (b3-b2)

Balzs Mik, Pter Hervay, Georgina Nra Tth, U

www.tankonyvtar.hu

CAD Book

Spline
(1)
(2)
(3)

p(t ) a3 t 3 a2 t 2 a1 t a0

p(0) a0
p(1) a3 a2 a1 a0

p' (1) 3 a3 2 a2 a1
p' (0) a1

p (0) r
i

pi (1) ri1

pi ' (1) pi1 ' (0)

pi "(1) pi 1"(0)

The simplest polynom, which has a constant 2nd derivative is the cubic spline (1).
The conditions of the continuity is the equality of the p(t) and the p(t) in the start and end
points (2).
The parameters of the ith segments are identified by the (3), but there is several results,
because the number of the unknown variables are higher then the number of equations.

www.tankonyvtar.hu

Balzs Mik, Pter Hervay, Georgina Nra Tth, U

2. Geometric fundaments of CAD systems

B-spline

r (t ) B0 (t ) r0 B1 (t ) r1 B2 (t ) r2 B3 (t ) r3
Weights:

(1 t ) 3
B0 (t )
6
1 3 (1 t ) 3 t (1 t ) 2
B1 (t )
6
1 3 t 3 (1 t ) t 2
B2 (t )
6
t3
B3 (t )
6

If the value of the derivatives are defined in the start and end points, the equation can be
solved. This is the B-spline.
The B-spline is
an approximation curve, it doesnt go through the control points,
the control points has not got any effects to the other segments.

Balzs Mik, Pter Hervay, Georgina Nra Tth, U

www.tankonyvtar.hu

CAD Book

Surfaces
Explicit definition:

x=x(u,v)
y=y(u,v)
z=z(u,v)

Implicit definition:

f(x,y,z)=0

u, v 0,1

Example: SPHERE

x xo R cos 2u sin v
y yo R sin 2u sin v
z zo R cos v

u, v 0,1
( x xo ) 2 ( y yo ) 2 ( z zo ) 2 R 2 0

The 3D surfaces can be defined by explicit and implicit equation, as the points or curves, but
in case of explicit surface definition two parameters are used (u,v). The values of them are
between 0 and 1.
The example shows the definition of a sphere, the centre of it is (xo, yo, zo), the radii is R.

www.tankonyvtar.hu

Balzs Mik, Pter Hervay, Georgina Nra Tth, U

2. Geometric fundaments of CAD systems

Quadratic surface
x

x
y
z 1 Q 0
z

1

If any parameters are quadratic, the surface call quadratic surface. These surfaces can be
described by homogenous form, where the Q factor matrix is constant in case of each
surfaces.
This format is suitable for describe sphere, cylinder, cone, hyperboloid, paraboloid etc.
These analytic surfaces are not suitable for describe the surfaces of a machine part,
therefore we have to use complex and freeform surfaces in the CAD system. The three most
known type of these surfaces are
Sweep surface
Ruled surface
Freeform or sculpture surface.

Balzs Mik, Pter Hervay, Georgina Nra Tth, U

www.tankonyvtar.hu

CAD Book

Sweep surface

D
G

In case of sweep surface two curve have to defined.

The first is an open or closed curve (D).
The second curve (G) will run along D with the constant contact point.
There is possible to use a rotation ((t)) function.
The plane, sphere, cylinder, cone can be defined as sweep surface.

www.tankonyvtar.hu

Balzs Mik, Pter Hervay, Georgina Nra Tth, U

2. Geometric fundaments of CAD systems

Ruled surface

The ruled surface is defined by three 3D curves.

The G curve drive along D1 curve and lean in D2.
In the first case the D1 and D2 are divided to equal segments, and the end points of these
segments are connected by G.
In the second case the G curve just lean to D1, and the G will be parallel in every position.
Other variation can be generated of ruled surface by application of a non constant G curve.

Balzs Mik, Pter Hervay, Georgina Nra Tth, U

www.tankonyvtar.hu

CAD Book

Freeform surfaces

(1) r (u, v)

u, v 0,1

m n

r
(
u
,
v
)

(2)
rij Bij (u, v)

u, v 0,1

i 0 j 0

(3) Bij (u, v) n u i (1 u) ni m v i (1 v) m j

If a surface cannot be describe by analytic or moving of curves, they are called freeform or
sculpture surfaces. The mathematic presentation of these surfaces are similar to the spline
curves, control points are used to determine the surface.
The parametric surface description uses two variables (u,v), and the surface is identified by
weight functions (1)(2), like in case of curves.
The Bzier-surface uses Bzier curves as control geometry (3).

www.tankonyvtar.hu

Balzs Mik, Pter Hervay, Georgina Nra Tth, U

2. Geometric fundaments of CAD systems

TRANSFORMATIONS

Balzs Mik, Pter Hervay, Georgina Nra Tth, U

www.tankonyvtar.hu

CAD Book

Translation

x1 t1
r* r t x2 t 2
x3 t3
t1
t t 2
t 3

t
r*
x2

t: translation vector

The defined geometric elements should be modified or transformed in a CAD system. This
transformation is done by point-by-point, so we have to understand the manipulation
methods of a point.
The simplest transformation is the translation, when the point, which is represented with r
vector, is moved by t vector.

www.tankonyvtar.hu

Balzs Mik, Pter Hervay, Georgina Nra Tth, U

2. Geometric fundaments of CAD systems

Scaling

x3
r r*
x2

C>0

C 0 0 r1 C r1
r* C r 0 C 0 r2 C r2
0 0 C r3 C r3

In case of scaling, every coordinate values are multiple with a constant. These constants can
be same, this is the uniform scaling, or these factors can be different. The scaling is
calculated by matrix multiplication, where C is the scaling matrix.

Balzs Mik, Pter Hervay, Georgina Nra Tth, U

www.tankonyvtar.hu

CAD Book

Rotation about xi
Rotation around x1 with 1
Rotation around x2 with 2
Rotation around x3 with 3

r* F 1 r
r* F 2 r
r* F 3 r

r*
1
r

r*=F2 F1 r

0
0
1
F 1 0 cos 1 sin 1
0 sin 1 cos 1
cos 2 0 sin 2
F 2 0
1
0
sin 2 0 cos 2
cos 3 sin 3 0
F 3 sin 3 cos 3 0
0
0
1

The rotation of an object means the rotation around a xi coordinate axes with a i angle. If
the rotation is performed around a general line, the coordinate system has to be transformed
to the direction of the line.
The rotation is calculated by matrix multiplication, where Fi is the rotation matrix. The order
of the multiplication is important if more rotations are applied.

www.tankonyvtar.hu

Balzs Mik, Pter Hervay, Georgina Nra Tth, U

2. Geometric fundaments of CAD systems

Mirror to plane
r* S 1 r
Mirror to [x1, x3] plane: r* S 2 r
Mirror to [x1, x2] plane: r* S 3 r

x3
x1

Mirror to [x2, x3] plane:

r*
r
x2
1 0 0
S 1 0 1 0
0 0 1

1 0 0
S 2 0 1 0
0 0 1

1 0 0
S 3 0 1 0
0 0 1

The mirror of an object has different ways. The first is the mirror to coordinate plane.
We use matrix multiplications, as previous. Si is the mirror matrix. The matrix is very simple,
depends on the actual plane, the sign of appropriate coordinate value is changed.

Balzs Mik, Pter Hervay, Georgina Nra Tth, U

www.tankonyvtar.hu

CAD Book

Mirror to xi axes
Mirror to x1 axes:

r* S 2,3 r
Mirror to x2 axes:

r* S 1,3 r
Mirror to x3 axes:

S 2, 3

r* S 1,2 r

1 0 0
1 0 0
1 0 0

0 1 0 S 1,3 0 1 0 S 1, 2 0 1 0
0 0 1
0 0 1
0 0 1

The second way is the mirror to xi axes. As the Si,j mirror matrix shows, the signs of the values
of coordinate axis are changed, expect the xi.

www.tankonyvtar.hu

Balzs Mik, Pter Hervay, Georgina Nra Tth, U

2. Geometric fundaments of CAD systems

Mirror to the origin

r* S r
1 0 0
S 0 1 0
0 0 1

x2
r

The mirror to the origin is very simple, every sign of the coordinate values have to be
changed. Therefore the mirror matrix contains -1 in the main diagonal.

Balzs Mik, Pter Hervay, Georgina Nra Tth, U

www.tankonyvtar.hu

CAD Book

PROJECTION FOR DISPLAY

www.tankonyvtar.hu

Balzs Mik, Pter Hervay, Georgina Nra Tth, U

2. Geometric fundaments of CAD systems

Projection

c2 x2 cos 2
c1 x1 cos 1

x1
x 1

2
2
x3

c1 x1

c3 x3

c2 x2 sin 2

c2 x2
1 c2 x2 cos 2 c1 x1 cos 1

2 c3 x3 c 2 x2 sin 2 c1 x1 sin 1
1 c1 cos 1
c sin
1
2 1

c 2 cos 2

c 2 sin 2

c1 x1 sin 1

x1

x2
x
3

The core of the CAD system (kernel) compute the 2D coordinate values () to the display the
3D object (r). The connection between the two vectors is computed by matrix multiplication
( = A r). The A matrix is the projection matrix.
Based on the picture the A matrix can be defined easy.
The c1, c2, c3 factors show the scale on the xi axes, the 1, 2 angles show the angles between
the x1, x2 and 1 axis.

2. Geometric fundaments of CAD systems

DISPLAY AND SHADING

Balzs Mik, Pter Hervay, Georgina Nra Tth, U

www.tankonyvtar.hu

CAD Book

Wire-frame model, rendered and combined

model

The model helps organize and visualize products and high level goals or activities. The model
is complex and integrated. It would be the basic of analysis.
On the slide there are three types of display of the same model. Wire-frame model,
rendered, realistic model and rendered model.

(http://en.wikipedia.org/wiki/Wire-frame_model)

www.tankonyvtar.hu

Balzs Mik, Pter Hervay, Georgina Nra Tth, U

2. Geometric fundaments of CAD systems

Hidden surface determination

Algorithms:
Back face culling
Z-buffer algorithm
Raytracing
Recursive Raytracing

The hidden surface determination is the a process which use to determine which surfaces or
parts of surfaces are visible from a certain viewpoint. A hidden surface determination
algorithm is a solution to the visibility problem. The analogue for line rendering is hidden line
removal. Hidden surface determination is necessary to render an image correctly. So that
one cant look through walls in virtual reality.
Some algorithm which can be use for this problem are the back face culling, the ray-tracing,
the recursive ray-tracing of the Z-buffer algorithm.
(http://en.wikipedia.org/wiki/Hidden_face_removal)

Balzs Mik, Pter Hervay, Georgina Nra Tth, U

www.tankonyvtar.hu

CAD Book

Back-face culling

Back-face culling determines whether a polygon of a graphical object is visible. It is a step in

the graphical pipeline that tests whether the points in the polygon appear in clockwise or
counter-clockwise order when projected onto the screen. If the user has specified that frontfacing polygons have a clockwise winding, if the polygon projected on the screen has a
counter-clockwise winding it has been rotated to face away from the camera and will not be
drawn.
(http://en.wikipedia.org/wiki/Back-face_culling)

www.tankonyvtar.hu

Balzs Mik, Pter Hervay, Georgina Nra Tth, U

2. Geometric fundaments of CAD systems

On the slide the same model can be see. The difference is that the determines the parts of
the object visible. The first one is right and the second is wrong.

Balzs Mik, Pter Hervay, Georgina Nra Tth, U

www.tankonyvtar.hu

CAD Book

Z-buffer algorithm

Z-buffering is the management of image depth coordinates in 3D graphics. Its usually done
in hardware, sometimes in software. It is one solution to the visibility problem, which is the
problem of deciding which elements of a scene are visible, and which are hidden.
When an object is rendered by a 3D graphics card, the depth of a generated pixel is stored in
a buffer, the z-buffer. This buffer is usually arranged as a 2D array with one element for each
screen pixel. If another object of the scene must be rendered in the same pixel, the graphics
card compares the two depths and chooses the one closer to the observer. The chosen depth
is then saved to the z-buffer and replacing the old one. In the end, the z-buffer will allow the
graphics card to correctly reproduce the usual depth perception. A close object hides a
farther one.

www.tankonyvtar.hu

Balzs Mik, Pter Hervay, Georgina Nra Tth, U

2. Geometric fundaments of CAD systems

Ray-tracing

In computer graphics, ray tracing is a technique for generating an image by tracing the path
of light through pixels in an image plane and simulating the effects of its sections with virtual
objects. The technique is capable of producing a very high degree of visual realism, usually
higher than that of typical scan line rendering methods. This makes ray tracing best suited for
applications where the image can be rendered slowly ahead of time, such as in still images
and film and television special effects. Ray tracing is capable of simulating a wide variety of
optical effects, such as reflection and refraction, scattering, and dispersion.
Optical ray tracing describes a method for producing visual images constructed in 3D
computer graphics environments, with more photorealism than either ray casting or scan
line rendering techniques.
(http://en.wikipedia.org/wiki/Ray_tracing_(graphics))

Balzs Mik, Pter Hervay, Georgina Nra Tth, U

www.tankonyvtar.hu

CAD Book

The Recursive Ray Tracing Algorithm

Ray tracing follows reflected and refracted rays through a scene. The rays are thin, so aliasing
is a problem. Ray tracing can be used as a basic technique for volume rendering. Its a
recursive algorithm. It use secondary rays which are followed recursively from primary rays.
(http://cs.fit.edu/~wds/classes/adv-graphics/raytrace/raytrace.html
Pic.: http://en.wikipedia.org/wiki/File:Recursive_raytrace_of_a_sphere.png)

www.tankonyvtar.hu

Balzs Mik, Pter Hervay, Georgina Nra Tth, U

2. Geometric fundaments of CAD systems

Shading

Shading refers to representing depth perception in 3D models or illustrations by levels of

darkness, and the process of altering a colour based on its angle to lights and its distance
from lights to create a photorealistic effect. Shading is a part of the rendering process.
Shading alters the colours of faces in a 3D model based on the angle of the surface to a light
source or light sources.
The first image below has the faces of the box rendered, but all in the same colour. Edge lines
have been rendered here as well which makes the image easier to see.
The second image is the same model rendered without edge lines.

Balzs Mik, Pter Hervay, Georgina Nra Tth, U

www.tankonyvtar.hu

CAD Book

Lights

Lighting fixtures come in a wide variety of styles for functions. The most important functions
are as a holder for the light source, to provide directed light and to avoid visual glare. Some
are plain and functional and some are pieces of art in themselves.
There are many types of lights can be used. Spotlight, directional or point light for example.
(http://en.wikipedia.org/wiki/Lighting)

www.tankonyvtar.hu

Balzs Mik, Pter Hervay, Georgina Nra Tth, U

2. Geometric fundaments of CAD systems

Colours, colour code systems

Cyan

Blue

White

Blue
Magenta
Green

Green
Yellow

Yellow

Red

Black

Red

White

Cyan
Blue

Grey
Black

Red

RGB (Red, Green, Blue)

The RGB colour model is an additive colour model in which red, green, and blue light is
added together in various ways to reproduce a broad array of colours. The name of the
model comes from the initials of the three additive primary colours, red, green, and blue. [1]
CMY (cyan (C), magenta (M) , and yellow (Y))
It is possible to realize a large range of colours seen by combining cyan, magenta, and yellow
transparent inks. These are the subtractive primary colours. Often a fourth black is added to
improve reproduction of some dark colours. [2]
HLS
HSL is one of the most common cylindrical-coordinate representations of points in an RGB
colour model, which arrange the geometry of RGB in an attempt to be more intuitive and
perceptually relevant than the cube representation.
HSL stands for hue, saturation, and lightness. It is often called HLS. [2]
[1]
[2]

http://en.wikipedia.org/wiki/RGB_color_model
http://en.wikipedia.org/wiki/Color_model#HSV_and_HSL_representations

Balzs Mik, Pter Hervay, Georgina Nra Tth, U

www.tankonyvtar.hu

CAD Book

Textures

In computer graphics, texture filtering or texture smoothing is the method used to determine
the texture colour for a texture mapped pixel, using the colours of nearby pixels of the
texture. Mathematically, texture filtering is a type of anti-aliasing, but it filters out high
frequencies from the texture fill. It allows a texture to be applied at many different shapes,
sizes and angles while minimizing blurriness, shimmering and blocking.
(http://en.wikipedia.org/wiki/Texture_filtering)

www.tankonyvtar.hu

Balzs Mik, Pter Hervay, Georgina Nra Tth, U

2. Geometric fundaments of CAD systems

Rendered picture

Rendering is the process of generating an image from a model. A scene file contains objects
in a strictly defined language or data structure; it would contain geometry, viewpoint,
texture, lighting, and shading information as a description of the virtual scene. The data
contained in the scene file is then passed to a rendering program to be processed and output
to a digital image or raster graphics image file.
(http://en.wikipedia.org/wiki/Rendering_(computer_graphics))

Balzs Mik, Pter Hervay, Georgina Nra Tth, U

www.tankonyvtar.hu

Budapest University of
Technology and Economics

Szent Istvn
University

buda University

Typotex
Publishers

TMOP-4.1.2-08/A/KMR-0029

CAD Book
3. Geometric modelling
Authors: Lszl Molnr
Dr. Kroly Vradi

www.tankonyvtar.hu

Lszl Molnr, Kroly Vradi, BUT

3. Geometric modelling

Introduction
Generally speaking, a model is nothing but the copy of a real or
imagined object, mapping thereof using limited information. A
computerized geometric model maps up the shape and
dimensions of an object.
As a result of attempts to develop an ideal geometric modelling system,
there is a broad range of methods available today. Nevertheless, no
universal solution has been managed to be developed to satisfy all
demands for a geometric product model in itself. Known methods offer
different application options depending on product and task.
Experience shows that an appropriate in-depth familiarization with the
theoretical basics of geometric modelling systems enhances effective
modelling work, on the one hand, and accelerates the mastering of
CAD systems not used earlier.

Lszl Molnr, Kroly Vradi, BUT

www.tankonyvtar.hu

CAD Book

Introduction
From the topological point of view, geometric modelling systems can be
classified into two basic groups:
manifold modelling systems: they include modelling systems
suitable for modelling forms that can be mapped into a manifold of
2D points.
objects of a non-manifold topology are not realistic in general; they
cannot be mapped into a manifold of 2D points. This usually arises
from the fact that a model includes basic units of different dimensions
(1D, 2D or 3D) or the latter are interconnected within a model.

manifold

The octants resulting from the next breakdown of partially filled regions
constitute the third level of the hierarchic tree where the procedure
described earlier must be repeated.
This method, applying a so-called hierarchical decomposition method,
can provide accurate descriptions in case of objects delimited by
perpendicular plane surfaces, and only approximate descriptions in case
of oblique and curved surfaces. The accuracy of approximation can be
influenced by breakdown depth.
Advantages of the procedure include the fact that it is extremely simple
to express by algorithms and that its application does not require special
user skills.

www.tankonyvtar.hu

www.tankonyvtar.hu

CAD Book

Solid modelling Modelling by elemental cells

In modelling by elemental cells, components are built up by so-called
isomorphic cells, which are smaller by several orders of magnitude than
the component size. Modelling by elemental cells primarily serves as a
modelling tool for numerical procedures (finite element, boundary element
methods). The figures below show modelling by elemental cells, the 3D
geometric model of a component, and its finite element model made up of
small tetrahedron elements.

www.tankonyvtar.hu

Lszl Molnr, Kroly Vradi, BUT

3. Geometric modelling

Solid modelling Modelling by elemental solids

In modelling by elemental solids, components are built up of so-called
solid primitives, falling into the order of magnitude of their dimensions
and having a specific geometry, by using composition operations.

The English term for the modelling procedure to combine elemental solids
is:
Constructive Solid Geometry
or CSG modelling for short.
Modelling by elemental solids is the most widespread of all volumetric
modelling methods. Later on, this modelling form will be termed as solid
modelling.
A solid model provides a complete, characteristic and concise
description of an object, enabling integrated and automated design.

Lszl Molnr, Kroly Vradi, BUT

www.tankonyvtar.hu

CAD Book

Solid modelling Modelling by elemental solids

The two basic toolset groups of solid modelling are elemental geometric
solids Ti and composition operations ( is a summary indication of
composition (set) operations).
The complex solid T as in the figure is generated by adding primitives T1
and T2 and subtracting primitive T3.

T
T1

www.tankonyvtar.hu

Lszl Molnr, Kroly Vradi, BUT

3. Geometric modelling

Assumptions in solid modelling

an object is a rigid solid, meaning that it has a concrete and invariant
shape not affected by spatial location or position;
an object fills the space occupied by it homogeneously, meaning that
the inside of the object is always connected to the complementary of
the model through the cover;
object extension is finite, meaning that the model can be mapped for
computer display;
an object can be generated as a composition of a finite number of
elemental solids, meaning that an object model can be stored in a
computer;

an object can be modelled as a closed set in terms of rigid solid

motion.

Lszl Molnr, Kroly Vradi, BUT

www.tankonyvtar.hu

CAD Book

Solid modelling approach by the theory of sets

Let the space regions occupied by elemental geometric solids (solid
primitives) be:

T1, T2, T3 . . . Ti . . . Tn
A complex solid, that is, an object, can be generated by the composition
of elemental geometric solids:

T = (Ti)

1in

where indicates possible composition operations:

union;

difference;

intersection.

www.tankonyvtar.hu

Lszl Molnr, Kroly Vradi, BUT

3. Geometric modelling

Solid modelling approach by the theory of sets

The previous equation developed:

T = ((((T1) T2) T3) . . .)

If the regions Ti are regular, the equation above produces a
mathematically complete and unique result object, but the composition
(the method of generation) is not unambiguous. This means that the same
result object can be generated from other solid primitives Ti and by other
composition operations as well.
Geometrically, the size of elemental geometric solids Ti is similar to the
order of magnitude of the model T and their number is finite.

Lszl Molnr, Kroly Vradi, BUT

www.tankonyvtar.hu

CAD Book

Solid modelling approach by the theory of sets

If the regions Ti are regular,

the result object will be complete and unique.

www.tankonyvtar.hu

Lszl Molnr, Kroly Vradi, BUT

3. Geometric modelling

Solid modelling approach by the theory of sets

The solid model T is defined as a point set in space. The limits of the
object divide space into an external and internal point set. By introducing
the following signage:
bT

is the inside of the model;

is the boundary of the model;

is the complementary set of points of the model

(that is, the points outside of it).

The complete model space can be stated as follows:

M = bT kT hT
The model itself, representing the inside of the model and the boundary of
the model:

T= bT hT = bhT
The mantle model: hT

Lszl Molnr, Kroly Vradi, BUT

www.tankonyvtar.hu

CAD Book

Solid modelling approach by the theory of sets

Regions Ti must be closed and regular. A region T is regular if the
following condition is met:

T=hbT

Example of a non-regular region.

www.tankonyvtar.hu

Lszl Molnr, Kroly Vradi, BUT

3. Geometric modelling

Solid modelling approach by the theory of sets

A special area of solid modelling, not at all unproblematic, is to find out
whether certain points are included in a given region. Inclusion
information is important for
surface-like display;
engineering quantity calculations;
crash tests.
The following example shows three relations between the points of a set
V intersecting a regular set T.

P bT inside;
Inside (V,T)

Outside (V,T)
Boundary (V,T)

Boundary (V,T)

Inside (V,T)

P hT boundary;
P kT outside.

Lszl Molnr, Kroly Vradi, BUT

www.tankonyvtar.hu

CAD Book

Tools for solid modelling

The toolset for solid modelling includes the following:
creation of solid primitives;
composition operations;
manipulation of solid primitives and solids;
illustration.
Creation of solid primitives
Elemental solids, also named as solid primitives can be pre-defined or
created by the user. Pre-defined solid primitives include:
rectangle

wedge;

cylinder;

cone;

torus;

sphere.

www.tankonyvtar.hu

Lszl Molnr, Kroly Vradi, BUT

3. Geometric modelling

Tools for solid modelling

Pre-defined solid primitives

Some softwares may include additional solid primitives; e.g. cone,
convex arc, concave arc, etc.

Lszl Molnr, Kroly Vradi, BUT

www.tankonyvtar.hu

CAD Book

Tools for solid modelling

User-created solid primitives:
extrude;
revolve;

(sweep);

(loft).

User-created solid primitives

A common feature of user-created solid primitives is that they can be
created by moving surfaces.

www.tankonyvtar.hu

Lszl Molnr, Kroly Vradi, BUT

3. Geometric modelling

Tools for solid modelling

shade + hide

www.tankonyvtar.hu

CAD Book

Tools for solid modelling

rotating illustration

with material
specifications

www.tankonyvtar.hu

Lszl Molnr, Kroly Vradi, BUT

3. Geometric modelling

Solid modelling

In practice, the solid modelling process consists of defining solid

primitives, adjusting dimensions, transformation into the appropriate
position, and the application of generalized set operations. The benefit of
combining elemental solids is that it ensures verisimilitude for the model
produced.

Lszl Molnr, Kroly Vradi, BUT

www.tankonyvtar.hu

100

CAD Book

Example for producing a solid model

www.tankonyvtar.hu

Lszl Molnr, Kroly Vradi, BUT

3. Geometric modelling

101

Example for producing a solid model

Solid primitives required for producing a solid:

T2 (35x10)

T1 (120x35x10)
T3 (12x10)

T5 (30x10x60)
T8 (24x35)

T4 (60x35x50)
T6 (18x10x60)
T7 (12x12x35)

T9 (5x5x45)

Lszl Molnr, Kroly Vradi, BUT

www.tankonyvtar.hu

102

CAD Book

Example for producing a solid model

Model design process (1/4)

T1=(((T1)T2)T2)

www.tankonyvtar.hu

T2=(((T1)/T3)/T3)

Lszl Molnr, Kroly Vradi, BUT

3. Geometric modelling

103

Example for producing a solid model

Model design process (2/4)

T3=((T2)T4)

Lszl Molnr, Kroly Vradi, BUT

T4=((T3)/T5)

www.tankonyvtar.hu

104

CAD Book

Example for producing a solid model

Model design process (3/4)

T5=((T4)/T6)

www.tankonyvtar.hu

T6=(((T5)T7)T7)

Lszl Molnr, Kroly Vradi, BUT

3. Geometric modelling

In terms of design, products and their various parts can be interpreted as

objects, while features are characteristics associated with them.
Relations between characteristics are described and regulated by
correlations and restrictions.
As regards mechanical products, the geometric form is of primary
importance in respect of material realization, therefore it seems to be
natural that features should be derived from geometry here.

Lszl Molnr, Kroly Vradi, BUT

www.tankonyvtar.hu

110

CAD Book

Features
The characteristics induced by a geometric form are defined as features
of shape.
Similarly to objects, processes also have quality
characteristics; they are called features of process.

and

quantity

Characteristics of the operation of mechanical structures can be

summarized as features of operation. Natural scientific phenomena
serving as a basis for product operation are termed features of meaning.
Features can be interpreted according to three approaches:

geometric interpretation;

application-oriented interpretation;

ontologic interpretation.

www.tankonyvtar.hu

Lszl Molnr, Kroly Vradi, BUT

4. Feature-based geometric modelling

111

Geometric interpretation of features

According to the geometric interpretation, features can be considered as
a set of information containing the logical association of the points,
edges, and surfaces of a component.

Perpendicular edges
Offset edges
Perpendicular
surfaces
Perpendicular surfaces

Offset surfaces

Hole

Lszl Molnr, Kroly Vradi, BUT

www.tankonyvtar.hu

112

CAD Book

Geometric interpretation of features

Another way of geometric interpretation is to take application concerns
more into consideration: a feature is a basic geometric unit
constituting that given area of the shape of the object modelled
which is of importance as regards product realization.
Rib
Piercing
Plane step

Chamfer

Hole

www.tankonyvtar.hu

Incision

Lszl Molnr, Kroly Vradi, BUT

4. Feature-based geometric modelling

113

Geometric interpretation of features

A geometric approach to the interpretation of features is problematic
because it is not explicit.
Rib
Piercing

For a designer, a rib as a loadbearing element is a basic

feature. For a technologist, a rib
as a unit to be shaped is a
basic element. If both are
integrated in the model, it will
become over-defined.

Breakdown of an object into features is not explicit as it depends on the

purpose of utilizing the model.

Lszl Molnr, Kroly Vradi, BUT

www.tankonyvtar.hu

114

CAD Book

Semantic interpretation of features

More advanced tools for modelling geometric features already enable the
management of attributive information in addition to shape,
constituting the first step towards semantic orientation. According to the
semantic interpretation of features, they can be classified into shapegenerating, shape-modifying, shape-independent and shape-neutral
feature types.
A shape-generating feature means a closed form required to perform a
function. It is also termed as a carrier form.

Shape-generating

www.tankonyvtar.hu

Lszl Molnr, Kroly Vradi, BUT

4. Feature-based geometric modelling

115

Semantic interpretation of features

Shape-modifying features modify carrier features based on production,
installation, strength, etc. considerations.

Shape-modifying

Lszl Molnr, Kroly Vradi, BUT

www.tankonyvtar.hu

116

CAD Book

Semantic interpretation of features

Shape-independent features are linked to the nominal shape, causing
only its secondary modification, though. This modification is not followed
by the geometry; it is only included in the technical specifications. Such
shape-independent features include dimension tolerance, surface
roughness, surface treatment, etc.

Nitrated

www.tankonyvtar.hu

Shape-independent

Lszl Molnr, Kroly Vradi, BUT

4. Feature-based geometric modelling

117

Semantic interpretation of features

Shape-neutral features are not directly related to geometry; they are
treated as attributes only. They include material quality, heat treatment
requirements, etc.

Nitrated

Shape-neutral

Material: A60

Lszl Molnr, Kroly Vradi, BUT

www.tankonyvtar.hu

118

CAD Book

Ontologic interpretation of features

The ontologic interpretation of features is in the research phase at

present. In the ontologic interpretation, features constitute high-level basic
units of a product description language.

www.tankonyvtar.hu

Lszl Molnr, Kroly Vradi, BUT

4. Feature-based geometric modelling

119

Application-related features

Production technology features

Forms to be shaped and detached by a rotating cutting tool are
described by production technology features. Production
technology features can usually be derived directly from design
features.
Piercing
Rib

Chamfer
Plane step

Incision
Chamfer

Lszl Molnr, Kroly Vradi, BUT

Cylindrical hole

www.tankonyvtar.hu

120

CAD Book

Application-related features
Analysis features
Analysis features are associated with the idealizability of the geometric
model used as a basis for strength tests, with the support and load
criteria of the model. Accordingly, there are:

substituting features;

impact mediating features.

www.tankonyvtar.hu

Lszl Molnr, Kroly Vradi, BUT

4. Feature-based geometric modelling

121

Application-related features
Installation features
The assembly relations and connection quality of components and parts
can be characterized by installation features. These include:

features in a direct connection;

(these components are in contact or in a specific geometric
relation with each other along their surfaces, edges or
characteristic points).

features with an indirect impact;

(they describe inclusion or a spatial relationship arising from an
arrangement structure).

features describing manageability;

(they express the possible forms of connection of fixing,
installation and support tools).

Lszl Molnr, Kroly Vradi, BUT

www.tankonyvtar.hu

122

CAD Book

Component modelling
In the course of design, the initially conceived shape must be modified
several times before reaching the final shape. This is required so
because there are function, strength, quality, production, installation, etc.
criteria for a form, which can only be implemented and checked
separately or parallelly at best. Today, CAD systems are already
required to support the interactive production of design modifications. To
our current knowledge, this expectation is met by feature-based
softwares when models are determined by geometric and dimensional
constraints.
All 3D modelling systems available today are feature-based parametric
modelling tools. The most well-known and widespread feature-based
parametric design softwares are Mechanical Desktop, Inventor, Solid
Works, Solid Edge, Pro Engineer, Catia, NX, and Ideas. Component
modelling is a basic module of each system.

www.tankonyvtar.hu

4. Feature-based geometric modelling

125

Component modelling - Creating sketches

Example for applying geometric and dimensional constraints on a
sketch (1/4)

Task: complete the draft shown in the figure.

Lszl Molnr, Kroly Vradi, BUT

www.tankonyvtar.hu

126

CAD Book

Component modelling Creating sketches

Example for applying geometric and dimensional constraints on a
sketch (2/4)
Use drawing commands to draw
Combine the end points of the
the sketch which is at least
curves by using the coincident
topologically similar to the form
constraint.
to be created.

www.tankonyvtar.hu

Lszl Molnr, Kroly Vradi, BUT

4. Feature-based geometric modelling

127

Component modelling Creating sketches

Example for applying geometric and dimensional constraints on a
sketch (3/4)
The offset constraint can
The tangent constraint is used
specify that the two straight
to specify that straight lines and
lines should be parallel.
curves touch.

Lszl Molnr, Kroly Vradi, BUT

www.tankonyvtar.hu

128

CAD Book

Component modelling Creating sketches

Example for applying geometric and dimensional constraints on a
sketch (4/4)
The figure can
horizontal by a
constraint.

be made
horizontal

A sketch can be defined by dimensional

constraints.

www.tankonyvtar.hu

Lszl Molnr, Kroly Vradi, BUT

4. Feature-based geometric modelling

129

Component modelling Creating sketches

Notes to the work phase of creating sketches:

geometric and dimensional constraints can replace and substitute
each other;
softwares do not allow sketches to be over-specified;
constraints already set can be modified or deleted;
some softwares assist sketching by automatic constraints.

Lszl Molnr, Kroly Vradi, BUT

www.tankonyvtar.hu

130

CAD Book

Component modelling Creating features

Features can be classified into three basic groups:
sketch-based features;
located features;
work features.
Sketch-based features can be generated
from previously created sketches. The
feature created first the so-called base
feature can be based on a sketch only.

www.tankonyvtar.hu

Lszl Molnr, Kroly Vradi, BUT

4. Feature-based geometric modelling

131

Component modelling Creating features

Form elements frequently recurring in
design - hole, fillet, chamfer, etc. - can be
created without a sketch: they are termed
as located features.

Modelling is enhanced by work features.

The Union, Difference and Intersection

commands serve for executing set
operations between features.

Lszl Molnr, Kroly Vradi, BUT

www.tankonyvtar.hu

132

CAD Book

Component modelling Creating features

Example for creating features (1/4)
Task: produce the component below relying on the sketch created
earlier.

www.tankonyvtar.hu

Lszl Molnr, Kroly Vradi, BUT

4. Feature-based geometric modelling

133

Component modelling Creating features

Example for creating features (2/4)
Create a basic feature. Extrude the profile 20 mm upwards using the
Extrude command.

Lszl Molnr, Kroly Vradi, BUT

www.tankonyvtar.hu

134

CAD Book

Component modelling Creating features

Example for creating features (3/4)
Make a recess sketch.

www.tankonyvtar.hu

Extrude the profile in difference

mode.

Lszl Molnr, Kroly Vradi, BUT

4. Feature-based geometric modelling

135

Component modelling Creating features

Example for creating features (4/4)
Create a chamfer by 1x45 as
a located feature.

Lszl Molnr, Kroly Vradi, BUT

Create a 8 hole as a located

feature.

www.tankonyvtar.hu

136

CAD Book

Component modelling Creating features

Component created by
revolving

Component created
by lofting

Component created by sweeping

Study of
refraction

www.tankonyvtar.hu

Lszl Molnr, Kroly Vradi, BUT

4. Feature-based geometric modelling

137

Component modelling Some fine components

Lszl Molnr, Kroly Vradi, BUT

www.tankonyvtar.hu

138

CAD Book

Component modelling Some fine components

www.tankonyvtar.hu

Lszl Molnr, Kroly Vradi, BUT

4. Feature-based geometric modelling

139

Component modelling Plate models

An individual chapter of component modelling is represented by plate
component design, plate bending, cutting, spreading, etc. by special
plate commands.

Lszl Molnr, Kroly Vradi, BUT

www.tankonyvtar.hu

Budapest University of
Technology and Economics

Szent Istvn
University

buda University

Typotex
Publishers

TMOP-4.1.2-08/A/KMR-0029

CAD Book
5. Attributive information
and engineering calculations
Author: Olivr Papp

www.tankonyvtar.hu

Olivr Papp, BUT

5. Attributive information and engineering calculations

141

Introduction
In essence, attributive information
represents the properties of a
Windows-based file, helping to
identify, classify and group the file
concerned.
It includes, for instance, an
informative name, the name of the
author, the subject, and key words
or other important information within
a file.
All 3D design softwares add extra
information
to
components,
assemblies and drawings. Some of
the
additional
information
is
automatically added to the files, and
they can also be extended by
individual attributes.

Olivr Papp, BUT

www.tankonyvtar.hu

142

CAD Book

Grouping attributive information

Automatic. Automatic properties are generated by the application when
saving files. They include the properties referring to the date of creation,
the date and time of the last modification and the size of the file.
Pre-defined. Pre-defined properties already exist as early as producing
the components, but the user must specify the exact values. In general,
these properties are listed in a modifiable external text file and defined in
the component / assembly template. Pre-defined property types include
text, date, yes / no and numerical value.
Customized. Customized properties are created by the user; they include
values valid for the entire document.
Configuration-dependent. Similarly to the categories above, values of
this type of properties can be of several kinds, but their scope only
extends to single configurations. There a number of customized attributes
that are updated automatically when the component / attribute is
changed, such as properties containing the weight or material of
components.

www.tankonyvtar.hu

Olivr Papp, BUT

5. Attributive information and engineering calculations

143

Using file attributes

Components, assemblies and drawings. File properties can be used
for creating parametric legends: legends of drawings enclosed to the
properties of a file and are automatically updated when the values are
changed.
Assemblies. File properties can be used effectively to select and hide /
show components. For example, to hide / show all the connectors or
commercial goods from the assembly concerned at the same time, to
select all the components created by a given designer or to group
components by material.
Working drawings. File properties can be used to fill in automatically the
text field of the drawing sheet, the component list, the revision block,
legends and production notes.

Olivr Papp, BUT

www.tankonyvtar.hu

144

CAD Book

Entering customized information

File properties can be created directly within the file or by methods
specified in the 3D design system.
Direct approach. File properties are created directly within the file, using
Windows explorer or other file manager software.
Custom tab. By clicking on the File menu point in a 3D design system,
you can modify and extend file properties. The customized attributes of a
component / assembly can be specified through this window. Options
include direct manual entry or the use of pre-defined lists.

Example
for
specifying mass
properties as a
customized
file
property.

www.tankonyvtar.hu

Olivr Papp, BUT

5. Attributive information and engineering calculations

145

Entering customized information

Using designers spreadsheets / tables.
When producing a component set, you can also
use a so-called designers table by which you
can assign customized attributes to a
component (and to its configurations), for
instance.
PDM / PLM system use. PDM is a Product Data Management system
enabling a 3D design system to store and group data on a central server.
This can be really used for team work. When components / assemblies
are copied to the server, files are automatically extended by attributes,
such as serial number, status, name, project name, revision. A PDM can
also be configured to extend files by customized variables defined by the
system administrator.

Olivr Papp, BUT

www.tankonyvtar.hu

146

CAD Book

Extracting component-related information

The two commonest examples for extracting attributive information on a
3D component are the text field of the working drawing about the
component and the table including the part list of the component. Both
the text field and the part list table extract and display component data by
the Assign to property command (or an equivalent).
By a properly prepared working drawing template, a designer can save
as much as an hours work each day. As shown in the figure below, the
information in blue is automatically filled in the drawing sheet when the
model is inserted.

www.tankonyvtar.hu

Olivr Papp, BUT

5. Attributive information and engineering calculations

147

Intelligent feature catalogue

The intelligent feature catalogue or library operation is a frequently used
operation or combination of operations which is generated once and
saved into the library for further use.
Library operations generally consist of operations added to the basic
operation, rather than the basic operation itself. As a single model
cannot include two basic operations, no basic operation can be inserted
in a model already including a basic operation. However, it is possible to
create a library operation containing the basic operation and to insert it
in an empty model.
Users can create generally used operations such as holes or grooves
and save them as library operations. A number of library operations can
be used as building elements for a single model to save time and enable
model consistency.

Olivr Papp, BUT

www.tankonyvtar.hu

148

CAD Book

General features
Library operations can be used for performing any of the following:
Select configuration while inserting library operation in a model.
Record reference to parent model.
Edit by swapping configurations, selecting another position, etc.
Add descriptions to references when saving library operation.
Add drawing signs to library operation and insert them in the model
together with the library operation.
(When inserting a drawing sign into a library operation, either the
drawing sign itself or the pointer must touch the operation to be saved
by such operation.)

www.tankonyvtar.hu

Olivr Papp, BUT

5. Attributive information and engineering calculations

149

General features
Save helix as a library operation.
Change sketch perspective when inserting the library operation by
clicking on the arrow showing sketch perspective in the graphic area.

Transfer visual properties specified in the library operation, e.g.

patterns to the operations inserted.

Olivr Papp, BUT

www.tankonyvtar.hu

150

CAD Book

Design Library
The Design Library contains folders
including reusable elements such as
drawing signs, assemblies and forming
tools. The Design Library manages all
library operations, including the following:
Display
library
operations
and
subfolders
containing
library
operations.
Preview library operation models.
Design Library.
Insert library operation into a surface
element of a model or into a plane in
the graphic area.

www.tankonyvtar.hu

Olivr Papp, BUT

5. Attributive information and engineering calculations

151

Creating library operations

In order to create a library operation, the first task is to create a basic
operation to which the designer will add the operations intended to be
included in the library operation. In general, library operations are saved
as separate file types. The structure of the library operation affects the
way of performing the following:
Position library operation on the model.
Edit position of library operation.
While building up a library operation you can decide whether to include or
exclude references.
References. In order to create a library operation to contain references,
the library operation needs to be dimensioned in proportion to the basic
model on which it was created. References generate dimensions to
position library operations on the model.

Olivr Papp, BUT

www.tankonyvtar.hu

152

CAD Book

Creating library operations

No reference dimensions are required for library operations with surface
element references e.g. fillets.
References can also be created by using relationships. For instance, a
reference is created by adjusting the center point of an arc horizontally,
vertically or coincidently to the sketch origin.
Location. In order to generate a library operation without references, you
should create a library operation without dimensions or relationships
defined in relation to the basic model. Instead of the references used for
positioning the library operation, a sketch of the library operation is edited
and this sketch is positioned in relation to the model.
No library operation model can be generated from a multibody model
document.

www.tankonyvtar.hu

Olivr Papp, BUT

5. Attributive information and engineering calculations

153

Creating library operations

Process of creating a library operation.
1. Open a new model and draw a sketch and create a basic operation
from it.
2. Create the operations intended to be included in the library operation.
After creating a model containing several extruded operations and
intended to be saved as library operations, ensure that the Link
Results option is selected. This ensures that all operations are
included when the library operation is dragged onto the model.
3. Define the position of the library operation when adding it to the model:
References. Dimensioning operations to base.
Or
Location. Excluding dimensions or relationships between the
operation and the base.

Olivr Papp, BUT

www.tankonyvtar.hu

154

CAD Book

Creating library operations

Using references

Using location

4. Add further configurations after creating operations.

5. Close sketch and complete the following:
Click on the Design Library tab on the Task sheet.
Select the Design Library tab.
Select the folder where the library operation is intended to be
added.

www.tankonyvtar.hu

Olivr Papp, BUT

5. Attributive information and engineering calculations

155

Creating library operations

In the Operations Manager design tree, select the operations to
be saved as library operations.
Do not include the basic operation as part of the library
operation. If the basic operation is included, the base will form a
part of the library operation when it is dragged onto the model.
Hold down the Ctrl key and drag the operation to the bottom
panel of the Task sheet.
Subtraction of some operations may cause reconstruction errors
in the library operation model due to unresolved dependencies.
6. Specify the name and one of the following (optional) in the Save As
dialogue box:
Provide a description.
Select the Save As Copy option.
Click on the References key to display the Save As With
References dialogue box.

Olivr Papp, BUT

Olivr Papp, BUT

www.tankonyvtar.hu

162

CAD Book

Engineering calculations (Wall thickness analysis)

The calculation tool for wall thickness analysis can be used for checking
component wall thickness. It can be particularly useful in the design of
die-cast plastic components or moulds of thin walls, where sudden wall
thickness changes are intended to be avoided.
Wall thickness analysis can be used for the following:
To identify thick and thin areas within a component (particularly in
case of plastic components and moulds)
To identify surfaces of a given thickness
To detect regions which are potential hazards or sensitive to damage
To provide design support for moulds and die-cast components

www.tankonyvtar.hu

Olivr Papp, BUT

5. Attributive information and engineering calculations

163

Manufacturers catalogues on the Internet

As 3D design systems have become increasingly widespread in industry
and in everyday life as well, a demand has sprung up in construction
engineers to be able to download commercially available components
and assemblies from the Internet and integrate them into their designs.
Initially, 3D models were provided by companies through drawing on their
own resources, on CDs enclosed to their product catalogues, which is
increasingly replaced by content to be downloaded from the Internet free
of charge or for payment.
There are a number of businesses specialized in modelling the
commercially available products of companies (to be built in target
machinery) in 3D and to publish them on their webpage.
Some examples of models available this way: hundreds of SKF bearings,
aluminum profiles, cooling ribs, switches, rollers, pumps and motors
At present, there are millions of 3D models available through the Internet.

Olivr Papp, BUT

www.tankonyvtar.hu

164

CAD Book

Manufacturers catalogues on the Internet

3D ContentCentral
3D ContentCentral is a free storage, configuration and download
content center for 3D models, components and assemblies, as well as
2D blocks, library operations and macros.
With more than half a million registered users, this is the largest 3D
online community today. After joining by simple e-mail registration the
models selected can be downloaded. Anyone can upload their own
models to the content center to increase the number of components
available on an on-going basis.
As a supplier service, industrial component manufacturers and suppliers
can also upload their components to 3D ContentCentral free of charge.
The webpage provides them with further tools so that they can offer upto-date information to construction engineers. A number of 3D design
programs already provide options for direct uploads to this Internet
location.

www.tankonyvtar.hu

Olivr Papp, BUT

5. Attributive information and engineering calculations

165

Designers Toolbox
The Designers Toolbox or simply Toolbox is a library of standard
connectors. This library can be used for applying pre-designed elements
standard components in your assembly.
The Toolbox is installed together with the 3D design system, enabling
users to insert commercially available fixing elements (screws, nuts,
shims, etc.) into their assemblies by just a few clicks.
They can be inserted manually or by automatic recognition of holeconnector pairs.
Manual. Select the appropriate connector from the Toolbox and drag it
into the assembly by holding down the left mouse button. Release the
mouse button over the appropriate hole. Standard components are
designed to connect automatically to the components below them by
coincident and concentric constraints when being inserted in the
assembly.

Olivr Papp, BUT

www.tankonyvtar.hu

166

CAD Book

Designers Toolbox
Automatic. When a hole is created on a component, the standard
dimensions of the hole are retrieved from a table by the system. The
same table can be used for assigning screw types to different hole types.
If the hole-connector pairs thus created are recorded in the system, the
holes selected in the assembly can be filled with connectors
automatically by clicking on the Quick Connector command.
Quick Connectors include a MateReferences connection setting which
contains two preset constraint links. The screw can be fit into the hole by
these preset constraint links. One of the constraints is Concentric: it is
responsible for the uniaxiality of the hole and the screw. The other one is
Coincident, which is responsible for the adjustment of the head of the
screw and the surface of the hole, thus the screw is completely seated at
the hole joint. You can also produce such preset connections for your
components.

www.tankonyvtar.hu

Olivr Papp, BUT

5. Attributive information and engineering calculations

167

Designers Toolbox
The Designers Toolbox includes a main component file of standard
dimensions and a database (SWBrowser.mdb) of component
dimensions and configuration data. When a standard component is
inserted in a new size into the assembly, the Toolbox updates the main
component file and adds a new configuration by the dimensions selected.
The Designers Toolbox supports international standards, including ANSI,
AS, BSI, CISC, DIN, GB, ISO, IS, JIS, and KS.

Olivr Papp, BUT

www.tankonyvtar.hu

Budapest University of
Technology and Economics

Szent Istvn
University

buda University

Typotex
Publishers

TMOP-4.1.2-08/A/KMR-0029

CAD Book
6. Modeling of Sheet Metal Parts
Author: Istvn Madarsz

www.tankonyvtar.hu

Istvn Madarsz, SZIU

6. Modeling of Sheet Metal Parts

169

Introduction, key notes

Material thickness
Bend radius
Bend angle
Neutral line
Neutral factor

Bend angle

Neutral thread

Istvn Madarsz, SZIU

www.tankonyvtar.hu

170

CAD Book

Manufacturing based design

Tool
Collision
Part

www.tankonyvtar.hu

Istvn Madarsz, SZIU

6. Modeling of Sheet Metal Parts

171

Sheet metal features I.

www.tankonyvtar.hu

176

CAD Book

Flat pattern calculation II.

Where:
k: legth of plastic zone
: bend angle
r: bend radius
n: neutral factor
s: material thickness

www.tankonyvtar.hu

Istvn Madarsz, SZIU

6. Modeling of Sheet Metal Parts

177

Flat pattern calculation III.

Where:
l: length of flat pattern
lj: length of a straight segments
ki: legth of plastic zones

Istvn Madarsz, SZIU

www.tankonyvtar.hu

Budapest University of
Technology and Economics

Szent Istvn
University

buda University

Typotex
Publishers

TMOP-4.1.2-08/A/KMR-0029

CAD Book
7. Surface modelling
Authors: Dr. Istvn Szab
Roland Csomai

www.tankonyvtar.hu

- szabo.istvan@gek.szie.hu
- csomai.roland@gek.szie.hu

Istvn Szab, Roland Csomai, SZIU

7. Surface modelling

179

1. Mathematical base of the

surface description
- Creating interactive surface with points and curves
- Surface representation by algorithm
Continual function with two variables:

Function of local vektor in Descartes-coordinate system:

*tangent sensitivity
Solve: the implicit mode
Implicit define methode:

Istvn Szab, Roland Csomai, SZIU

www.tankonyvtar.hu

180

CAD Book

1. Mathematical base of the surface plot

To compare, lets see an example, a sphere with center in zero!
The function with variables:

General parametric form of surface define:

The sphere parametric representation (R= radius)

www.tankonyvtar.hu

Istvn Szab, Roland Csomai, SZIU

7. Surface modelling

181

1. Mathematical base of the surface plot

If we want to define the border curves, we have to substitute the umin,
umax, vmin, vmax values into the parametric equation.
The border condition to adjacent patches:

This assure that come true the C0 continuity criteria.

The derivated parametric function come true the C1 continuity criteria:

Istvn Szab, Roland Csomai, SZIU

www.tankonyvtar.hu

182

CAD Book

1. Mathematical base of the surface plot

This listed conditions can use on the 4 border curves and on the 4
corner points. This cornerpoints have a twisted vektor:

The patches have a normal vector. This is used for NC programs and
for calculation of shadow:

www.tankonyvtar.hu

Istvn Szab, Roland Csomai, SZIU

7. Surface modelling

183

1. Mathematical base of the surface plot

- Finite number of discrate element
- m x n ordered parametric pair
10

-5

-10
10

-10
10
5

10
5

0
-5

-5
-10

-10

0
-5

-5
-10

-10

Parametric plot of sphere in different resolution of grid

Istvn Szab, Roland Csomai, SZIU

www.tankonyvtar.hu

184

CAD Book

2. Applied surfaces in the practice of the CAD

2.1. Analytical surface description
Parametric equation of a plane:

Methods to define a plane:

- Given the normal vector
and a point of the plane,

- Given a curvated surface and a

point where the plane is tangent.
- The plane close an optional angle
with an given plane.

www.tankonyvtar.hu

Istvn Szab, Roland Csomai, SZIU

7. Surface modelling

185

2.1. Analytical surface description

Lined surfaces:
- if a line is fixed to any point of
surface - this lines all points
are on this surface.
- the surface have two border
curves G1(u) and G2(u)
The local vector between curves:

G1(u)= P(u,0) and G2(u)= P(u,1)

Realignment:

Istvn Szab, Roland Csomai, SZIU

www.tankonyvtar.hu

186

CAD Book

2.1. Analytical surface description

Tabular surface:

- Special lined surface!

- The control curve: G(u)
- (n) element line by
fixed direction.

www.tankonyvtar.hu

Istvn Szab, Roland Csomai, SZIU

7. Surface modelling

187

2.1. Analytical surface description

Rotated surface:
- G (u) profile curve,
- R (u) radius calculated from axis of rotation,
- The axis of rotation coinsides with the
coordinate system [r(u) = x(u) ].
Equation of the control curve:

Parametric equation of the local vector:

Istvn Szab, Roland Csomai, SZIU

www.tankonyvtar.hu

188

CAD Book

2.2. Base of the synthetic surfaces description

- Description of complicated shapes (chasses, turbina blade),
- Polynomial based approximated and interpolated
parametric curves,
- Hermite kind of surface item description.
Hermite cubic splines arc:

In scalar form:

where: C is the algebraical coefficient

www.tankonyvtar.hu

Istvn Szab, Roland Csomai, SZIU

7. Surface modelling

189

2.2. Base of synthetic surfaces description

The algebraical coefficient in form of vektor:
T= Transposed Matrix
The parameter vektor equation:

Convert the group of equation to matrix form:

The tangents slope (Derivated Hermite equation):

Derivation

Istvn Szab, Roland Csomai, SZIU

www.tankonyvtar.hu

190

CAD Book

2.2. Base of synthetic surfaces description

If we have to define a concrete arch, the matrix can be described
with substituting the border conditions.
Given: P0 , P0 , P1 , P1 , u=0 s u=1.
Border conditions matrix:
B = [P0 P0 P1 P1]T
Substituted the four border conditions:
P0 = C0; P0 = C1;

P1 = C3+ C2+ C1+ C0;

P1 = 3C3+2C2+ C1

The coefficients from the four equations:

C0 = P0
C1 = P0
C2 = 3(P1-P0) - 2P0 P1
C3 = 2(P0-P1) + P0 + P1

www.tankonyvtar.hu

Istvn Szab, Roland Csomai, SZIU

7. Surface modelling

191

2.2. Base of synthetic surfaces description

Replaced the coefficients in to the basic equation:

The equation in matrix form (for the informatical manageability):

- MHer the Hermite matrix.

The curve's derivate in parametrical and matrixed form:

Istvn Szab, Roland Csomai, SZIU

www.tankonyvtar.hu

192

CAD Book

2.2. Base of synthetic surfaces description

A Hermite patches can be described by the given function of
Hermite curves:

- A curve can be described with 4 vectors or 12 scalar datas,

- To describe patches 16 vectors and 48 scalar datas are
needed for a precise description.
- The required parameters: 4 local vector of corner points,
2 tangent vector in all corner points (u and v direction).
Matrix form of the patchs equation:

where:

www.tankonyvtar.hu

Istvn Szab, Roland Csomai, SZIU

7. Surface modelling

193

2.2. Base of synthetic surfaces description

The algebraic coefficient:

Used the already known Hermite matrix:

The matrix of the border condition (16 elements):

- The 4 sub-matrix include all of the local-, tangent- and twist vectors.

Istvn Szab, Roland Csomai, SZIU

www.tankonyvtar.hu

194

CAD Book

2.2. Base of synthetic surfaces description

Derivates are describing the surface elements curves:

Used with Bernstein polynomial:

Pij are the control points, these creates polyeder

P(u,v) surface slick the polyeder of Pij

Description with MBEZ matrix as seen in Hermite surface defined:

www.tankonyvtar.hu

Istvn Szab, Roland Csomai, SZIU

7. Surface modelling

195

2.2. Base of synthetic surfaces description

The cubical spline based Bezier patch have 4x4 control points. These
local vectors are the base of the B border condition matrix.

MBEZ matrix:
Same multiply-surfaces can be describe with B-spline curves:

- maximum degree of curve is 3,

- degree of curve (k-1) depends on the
control points number,
- the parametrization depends on the
splines other preferences.

Istvn Szab, Roland Csomai, SZIU

www.tankonyvtar.hu

196

CAD Book

2.2. Base of synthetic surfaces description

B-spline as a cubical equation :

Where N i3(u) the cubical basis function

The basis functions general form for optional degree:

u i = vertex vector
- If the distance is equal between two adjacent vertex,
the spline designation is uniform.

www.tankonyvtar.hu

Istvn Szab, Roland Csomai, SZIU

7. Surface modelling

197

2.2. Base of synthetic surfaces description

The vertex vector:

0 j n+k
The basis function is zero if it is not on the given area:

- the curve is locally controlable,

- if we increase the degree of the curve, the spline will be smoother,
- if k=n+1 (degree of the curve equal with the control points number)
the curve will be Bezier spline.

Istvn Szab, Roland Csomai, SZIU

www.tankonyvtar.hu

198

CAD Book

2.2. Base of synthetic surfaces description

The surface description by B-spline:

NURBS surfaces Non Uniform Rational B-spline:

- not equal the distance between two adjacent vertex
- the base function is a quotient of polynoms
- we can modify the weight of control points with wi coefficient.
The base function:
The parametric function of NURBSs curves:

www.tankonyvtar.hu

Istvn Szab, Roland Csomai, SZIU

7. Surface modelling

199

2.2. Base of synthetic surfaces description

Description of a line by B-spline:

Where P0 and P1 are two points to define the line.

If we choose unit weight, we have the general equation:

The NURBS discription for free-surfaces:

Istvn Szab, Roland Csomai, SZIU

www.tankonyvtar.hu

200

CAD Book

3. Typical surface-operation
in the CAD systems
Input Data:

points, distances, angles,

relative position-constraints etc.

3.1. Extruded surfaces

Tabular surface
Control curve: from line, arc or
B-spline
Operation: extrude

www.tankonyvtar.hu

Istvn Szab, Roland Csomai, SZIU

7. Surface modelling

201

3.1. Extruded surfaces

Swept surface: a special extruded surface.

Two items of this surface:

- Control curve
- Base profil
Both can be:
- Opened curve or
- Closed loop

Istvn Szab, Roland Csomai, SZIU

www.tankonyvtar.hu

202

CAD Book

3.1. Extruded surfaces

Lofted surface: Added surface between two or more profiles.
Boundary condition for transition:
- Minimum 2 profiles,
- Sufficient distance
between profiles,
- Two opened or
two closed profiles possible
- Specially attention to
make a control point.

TWIST!

www.tankonyvtar.hu

Istvn Szab, Roland Csomai, SZIU

7. Surface modelling

203

3.2. Revolved surfaces

The basis of this surface, to define a curve and a central axis.

- Opened or
closed profile,
- Axis is a line
(every instance),
- The curve mustnt
cross the axis.

Istvn Szab, Roland Csomai, SZIU

www.tankonyvtar.hu

204

CAD Book

3.3. Preparation of multiple-surfaces

Mathematical background:

- Define two B-Splines,

- Both splines must be
sweep in the route, what
appoint the other spline.

www.tankonyvtar.hu

Istvn Szab, Roland Csomai, SZIU

7. Surface modelling

205

3.4. Surfaces check

Stripes analysis
to check the continuity of surfaces
Curvature analysis to visualise the parameters of curve

Surface curvature analysis

Cylinder with zebra - stripes

Istvn Szab, Roland Csomai, SZIU

www.tankonyvtar.hu

Budapest University of
Technology and Economics

Szent Istvn
University

buda University

Typotex
Publishers

TMOP-4.1.2-08/A/KMR-0029

CAD Book
8. Engineering, assembly modelling
Author: Lszl Rabb

www.tankonyvtar.hu

Lszl Rabb, BUT

8. Engineering, assembly modelling

Assembly geometric relationships

Heterogeneous relationships
Elements

Degree number

Sorting

point-point (ball socket)

subordinate

point-line (ball socket+slider)

subordinate

point-face (ball socket+pair of sliders)

subordinate

line-line parallel (ball socket+slider)

superior

line-face not applicable

Lszl Rabb, BUT

8. Engineering, assembly modelling

225

Assembly - operations
Inspection
geometric (analytic) check interference

kinematic adjustable assemblies

physical material and physical properties
statistic BOM

Lszl Rabb, BUT

www.tankonyvtar.hu

226

CAD Book

Assembly - operations
Application operations
embedded or referenced modeling method
Additive entities
assembly sketches
manufacturing data, views PMI

www.tankonyvtar.hu

Lszl Rabb, BUT

8. Engineering, assembly modelling

227

Assembly - operations
assembly features

material removing
welding

Simplified model

redundant model, fast using

Lszl Rabb, BUT

www.tankonyvtar.hu

228

CAD Book

Assembly effects of model building

The modeling technology determines the possible relationships to be used.
The assembly techniques depend on the modeling methods.
CSG method Boolean connections in the relationship chain, fix
dimensions
Parametric method the relationships can be defined with parameters,
there is an assembly structure, in which the parameters can be re-defined
direct method the connection is local geometry dependent, there is no
assembly structure, the assembly can only be interpreted relatively to the
latest state
synchronous method local geometry dependent, but srtuctured with
live rules, integrated consistently with the relationships, there is no
assembly structure, but there are procedural connections
hybrid method uses the synchronous and the parametric methods
simultaneously, consistently. The methods can be used and switched
freely, and can contain any proportion of synchronous and parametric
elements.

www.tankonyvtar.hu

Lszl Rabb, BUT

8. Engineering, assembly modelling

229

Assembly effects to the design

The traditional design method is the bottom-up method;
part subassembly assembly product
The effects of the environment can be considered better if the engineer
knows the parameters of the containing environment. The engineering
logic is the top-down method;
product adequate assembly structure part

Lszl Rabb, BUT

www.tankonyvtar.hu

Budapest University of
Technology and Economics

Szent Istvn
University

buda University

Typotex
Publishers

TMOP-4.1.2-08/A/KMR-0029

CAD Book
9. Kinematical Analysis in CAD Environment
Author: Dr. Lszl Ktai
katai.laszlo@gek.szie.hu

www.tankonyvtar.hu

Lszl Ktai, SZIU

9. Kinematical Analysis in CAD Environment

231

Introduction
The purpose of the computerised analysis of mechanisms course is
to acquaint you with the structure of mechanisms, to interpret the
various techniques of position and track calculation, to perform
velocity analysis, and to define the velocity of the combined body in
motion. Building on basic knowledge, the purpose is to teach model
creation steps for kinematic analysis and finally to demonstrate
possible application with case studies.

Keywords: mechanism, simulation, joint, kinematical analysis

Lszl Ktai, SZIU

www.tankonyvtar.hu

232

CAD Book

Main Topics
Basis of Mechanisms
3D Modell Building for kinematical analysis

Case study

www.tankonyvtar.hu

Lszl Ktai, SZIU

9. Kinematical Analysis in CAD Environment

233

Basis of Mechanisms
Driving member
The world of mechanism
Well defined construction,
which produces motion
and it could be described
with unambiguous law
of motion. (e.g.: crankshaft)

Link (member)

Joints
(pair or constraints)

Fixed link (base, frame)

Driven member

Structural construction of a
crank-shaft mechanism

Lszl Ktai, SZIU

www.tankonyvtar.hu

234

CAD Book

Basis of Mechanisms
Kinematical pairs (joints) and their character
DOF definition

Sketch and construction of revolute joint

Sketch and construction of translational

joint

www.tankonyvtar.hu

Lszl Ktai, SZIU

9. Kinematical Analysis in CAD Environment

235

Basis of Mechanisms
Sketch and construction of screw joint

Lszl Ktai, SZIU

9. Kinematical Analysis in CAD Environment

239

3D Modell Building for kinematical analysis

Criterias of 3D modell creation

Workflow of computer aided kinematical simulation

Lszl Ktai, SZIU

www.tankonyvtar.hu

240

CAD Book

3D Modell Building for kinematical analysis

Simplifyed modells
Absolute and relative coordinate systems - how to apply them when
defining the joints and members.

www.tankonyvtar.hu

Lszl Ktai, SZIU

9. Kinematical Analysis in CAD Environment

241

3D Modell Building for kinematical analysis

Importing 3D CAD solid modells

Simulating the real structure force,

load and stress analysis
Look for number of parts (just the most
important ones from the point of view of
mechanism operation.

Lszl Ktai, SZIU

www.tankonyvtar.hu

242

CAD Book

3D Modell Building for kinematical analysis

How to define joints

The basic joints type are build in the softwares.

Defining the centre of hole with an

auxiliary coordinate system for revolute
joint definition.

Do not forget to define the connection to the

background in the necessary parts.

www.tankonyvtar.hu

Lszl Ktai, SZIU

9. Kinematical Analysis in CAD Environment

243

3D Modell Building for kinematical analysis

Special connections (joints).
Point-curve constraints (enable or disable lift off).
Define spline on the necessary surface.

Lszl Ktai, SZIU

www.tankonyvtar.hu

9. Kinematical Analysis in CAD Environment

247

Case study
Analysis of a crank-shaft mechanism
3. Definition of the joints

Lszl Ktai, SZIU

www.tankonyvtar.hu

248

CAD Book

Case study
Analysis of a crank-shaft mechanism
Process of revolute joint creation

www.tankonyvtar.hu

Lszl Ktai, SZIU

9. Kinematical Analysis in CAD Environment

249

Case study
Analysis of a crank-shaft mechanism
Definition of translation joint
- place
- connected parts
- direction

Lszl Ktai, SZIU

www.tankonyvtar.hu

250

CAD Book

Case study
Results

Position of piston[m]

Analysis of a crank-shaft mechanism

0
-0,02

180

270

360

-0,04
-0,06
-0,08

Velocity of the piston[m/s]

Position of crank[degree]

253

Case study
Analysis of a Smidt-coupling
3. Definition of joints
- revolute joints
- connection to the background
- radial positioning

Lszl Ktai, SZIU

www.tankonyvtar.hu

254

CAD Book

Case study
Analysis of a Smidt-coupling
Operational parameters
- RPM
- Torque
- radial displacement

www.tankonyvtar.hu

Lszl Ktai, SZIU

9. Kinematical Analysis in CAD Environment

255

Case study
Analysis of a Smidt-coupling
Results:
- simulation (workability)
- RPM of the driven shaft
- force analysis of the connecting rods
- analysis of bolts load

Lszl Ktai, SZIU

www.tankonyvtar.hu

Budapest University of
Technology and Economics

Szent Istvn
University

buda University

Typotex
Publishers

TMOP-4.1.2-08/A/KMR-0029

CAD Book
10. Engineering drawing in CAD environment
Author: Dr. Balzs Mik
miko.balazs@bgk.uni-obuda.hu

K.L. Narayana, P. Kannaiah, K. Venkata Reddy Machine drawing New Age, New Delhi 3rd ed.
2006. ISBN 978-81-224-2518-5

www.tankonyvtar.hu

Balzs Mik, U

10. Engineering drawing in CAD environment

257

Part description
Speach
Text
Free sketch
Engineering drawing
CAD model

There are several possibilities to describe a machine parts geometry. Beside the speech, the
text and free hand sketch the typical media of it is the engineering drawing. The fundaments
of the engineering drawing is constantly in the last hundred years, but the CAD systems
added lot of possibilities to generate them and extend the contains of them.

Balzs Mik, U

www.tankonyvtar.hu

258

CAD Book

Modelling process
Part
modelling

Assembly

Engineering
drawing

Drawing
Based on 3D CAD model
Preparation in model space
Define view directions
Define section planes
Set parameter table

In a CAD system the engineer create a 3D virtual model of a part, and he can create an
assembly with using of more parts. The engineering drawing will generated based on this
model, so the media of the design is the 3D virtual space, not the drawing sheet. In order to
generate the drawing, some definitions are added in the virtual space, like the view
directions, sections and the contain of the parameter table.
Because of the associativity the drawing will show the actual state of the model.

www.tankonyvtar.hu

Balzs Mik, U

10. Engineering drawing in CAD environment

259

CAD support
Automatic generating of views from CAD model
Axonometric view

Follows lets summarize the possibilities of CAD support in the area of create engineering
drawing.
The first and the most useful is the automatic generation of views based on CAD model. The
designer has to focus on the 3D model only, the right and complete drawing representation is
the task of the CAD system. There are no missing lines, no bad projection.
We can generate not only the conventional view, but the axonometric view too, which is very
useful to interpret a drawing.

Balzs Mik, U

www.tankonyvtar.hu

260

CAD Book

CAD support
Automatic generation of sections
Automationg hatching

We can generate sections, and the hatching will generate automatically. Of course it need
some adjustment to set the aesthetic hatching angle and density or the non visible or non
sectioned parts.

www.tankonyvtar.hu

Balzs Mik, U

10. Engineering drawing in CAD environment

261

CAD support

Changeable sheet size

Predefine formats
Automatic text box
Automatic dimensioning
Tolerance
Automatic hole position table

We can change the size of the sheet during the drawing, so if the first choice is too small or
too big, we can increase or decrease it. The position of the views are changeable too and the
projected views will move with the main view.
We can define special sheet formats with textbox and layouts, and the textbox will fill up
based on 3D model's parameter table. So the basic data will define only in one place.
The dimensioning needs lot of time in the drawing process, but CAD systems ensure
automatic dimensioning. The system will appear the dimensions in the selected views. But
the system can draw up only that dimensions, which were defined during the modelling
process in the selected view plane. The efficient application of this function needs lot of
practice and forecast during the modelling.
The definition of tolerances can be set automatically too. The CAD systems can change the
formats of the tolerances, we can define them by ISO marks, or limits or upper and down
values etc.
Based on CAD model we can create a hole position table for the production. So the designed
should not collect the position of the holes by diameters and lengths, which takes time and
the automatic table is associative with the model.

Balzs Mik, U

10. Engineering drawing in CAD environment

269

provides useful information for assembling the machine, as this drawing reveals all parts of a
machine in their correct working position.
Catalogue drawing: Special assembly drawings are prepared for company catalogues. These
drawings show only the pertinent details and dimensions that would interest the potential
buyer.

Balzs Mik, U

www.tankonyvtar.hu

270

CAD Book

Classification of drawings
Assembly drawing

The assembly drawing shows the connection of parts. It visualize the layout of the machine,
the dimensions of the connection elements. The parts are identified by numbers and the bill
of material (BOM) shows the basic data of them.

www.tankonyvtar.hu

Balzs Mik, U

10. Engineering drawing in CAD environment

271

Classification of drawings
Assembly drawing
Assembly drawing for instruction manual
Exploded assembly drawing
Schematic assembly drawing

The assembly drawing has some sub-classes:

www.tankonyvtar.hu

274

CAD Book

Section / Half section / Auxilary section

Section

Half section

The details of a part or assembly can be presented by sectional views, hlaf sections or
auxilary sections.
A sectional view obtained by assuming that the object is completely cut by a plane is called a
full section or sectional view. The sectioned view provides all the inner details, better than
the unsectioned view with dotted lines for inner details. The cutting plane is represented by
its trace in the view from the front and the direction of sight to obtain the sectional view is
represented by the arrows.
A half sectional view is preferred for symmetrical objects. For a half section, the cutting
plane removes only one quarter of an object. For a symmetrical object, a half sectional view
is used to indicate both interior and exterior details in the same view. A a centre line is used
to separate
the halves of the half section.
Auxiliary sections may be used to supplement the principal views used in orthographic
projections. A sectional view projected on an auxiliary plane, inclined to the principal planes
of projection, shows the cross-sectional shapes of features such as arms, ribs and so on.

www.tankonyvtar.hu

Balzs Mik, U

10. Engineering drawing in CAD environment

275

Hatching
One direction
means same part
Not correct

Not correct

Correct
Not correct

Shafts, screws, keys

are not sectioned
and hatched

Hatching is generally used to show areas of sections. The simplest form of hatching is
generally adequate for the purpose, and may be continuous thin lines at a convenient angle,
preferably 45, to the principal outlines or lines of symmetry of the sections.
Separate areas of a section of the same component shall be hatched in an identical manner.
The hatching of adjacent components shall be carried out with different directions or
spacing. In case of large areas, the hatching may be limited to a zone, following the contour
of the hatched area.
Where sections of the same part in parallel planes are shown side by side, the hatching shall
be identical, but may be off-set along the dividing line between the sections. Hatching
should be interrupted when it is not possible to place inscriptions outside the hatched area.
Some rule about sectional views:
The one direction of hatching means same part
The shafts, screws, keys are not sectioned and hatched
The boundary of the section be a separated line
The pattern of the hatching characterizes the type of the material:
Metal: 45 continuous line
Plastic, rubber: 3 lines in 45
Balzs Mik, U

www.tankonyvtar.hu

276

CAD Book

Glass or transparent materials: 45 short line with end section

Liquid: short horizontal lines
Wood: wood similar pattern
Concrete / cement / granulated material: random point cloud

www.tankonyvtar.hu

Balzs Mik, U

10. Engineering drawing in CAD environment

277

Text information
Title block (title, ID number, designers name, material, scale,
weight, overall size, sheet size etc.)
CAD file name
General fillet and chamfer
General tolerances
Surface roughness
Wall thichness
Engraving text in the surface
Testing requirements
Modification data

The title block should lie within the drawing space such that, the location of it, containing
the identification of the drawing, is at the bottom right hand corner. This must be followed,
both for sheets positioned horizontally or vertically. The direction of viewing of the title
block should correspond in general with that of the drawing. The title block can have a
maximum length of 170 mm.
A typical title block, providing the following information:
Title of the drawing
Sheet number
Scale
Symbol, denoting the method of projection
Name of the firm
Initials of staff drawn, checked and approved.

Balzs Mik, U

www.tankonyvtar.hu

278

CAD Book

Datum elements for dimensioning

Design base = Manufacturing base Main base

The key element of the dimensioning of a machine part is the datum element. The datum
element is a geometric feature of the part, which is the reference of the identify of other
geometric features.
The datum element can be
Design datum, which is defined by the designer based on the functional viewpoints, or
Manufacturing datum, which consider the manufacturing viewpoints.
If these two type of datum are same, it call main datum.
On other classification the datum feature can be
Real geometric element, like the side of the part, or
Theoretical element, like the centre of a hole.

www.tankonyvtar.hu

Balzs Mik, U

10. Engineering drawing in CAD environment

279

The rule of dimensioning

7.
40

When the dimension system is defined the designer have to follow some roles and
directives.
Some important directives of dimensioning are follows:
Clarity
Readability
Aesthetic
Same feature in same view
Everything only once
Design, manufacturing and measure viewpoint in same time
The pictures show examples:
Use the manufactured surface, as base.
Use symmetric dimensioning, if the part is symmetric
Avoid the chain dimensioning cause the toleranceing
Use local base elements
Put the dimension line close to the surface
Use as short projection line as possible
Avoid redundant dimensioning
Avoid the chain dimensioning cause the tolerancing
Balzs Mik, U

www.tankonyvtar.hu

280

CAD Book

The rules of dimensioning

13.

10.

14.
11.

12.

Define the dimension of the machined surfaces

Take consider the method of machining
Take consider the method of machining
Take consider how can you measure the defined dimensions
Group the dimensions according to the machining setups
Group the dimensions according to the machining setups

www.tankonyvtar.hu

Balzs Mik, U

10. Engineering drawing in CAD environment

281

Tolerances
Tolerance = the admitted
error
Size
General tolerance
With limits
IT fits

Form
Position

Bilateral tolerance of equal variation

Unilateral tolerance with zero

variation in one direction

Bilateral tolerance of unequal variation

Maximum and minimum

size directly indicated

Because of the manufacturing inaccuracies every dimensions have tolerances. The tolerance
is the admitted error. We can talk about size, form and position tolerances.
The size tolerances can be defined by standard, when no visible tolerance on de dimension,
and the value of it is defined by tables. We can add the limits of the differences by numbers
of IT classification.
The form and position of the differences can be the next:
Bilateral tolerance of equal variation
Unilateral tolerance with zero variation in one direction
Bilateral tolerance of unequal variation
Maximum and minimum size directly indicated

Balzs Mik, U

www.tankonyvtar.hu

282

CAD Book

The figure shows the basic term of the size deviations and tolerances.
In case of hole and shaft, the tolerances will identify the fit of these two elements.

www.tankonyvtar.hu

Balzs Mik, U

10. Engineering drawing in CAD environment

283

Fitting

The ISO fitting definition makes easy to define the relation of shaft and hole.
The ISO mark, like 120H8, shows
The type of the object: the capital letter (H) marks the hole, the small letter (h) marks the
shaft.
The position of the tolerance zone (see the picture), and
The wide of the tolerance zone.
The recommended pairs of tolerances in case of different applications are listed in engineer
handbooks.

Balzs Mik, U

www.tankonyvtar.hu

284

CAD Book

Form, shape and position tolerances

The form variation is a variation of the actual condition of a form feature (surface, line) from
geometrically ideal form.
The position variation is a variation of the actual position of the form feature from the
geometrically ideal position, with reference to another form (datum) feature.
Geometrical tolerance is defined as the maximum permissible overall variation of form or
position of a feature.
Geometrical tolerances are used,
to specify the required accuracy in controlling the form of a feature,
to ensure correct functional positioning of the feature,
to ensure the interchangeability of components, and
to facilitate the assembly of mating components.
The tolerance of form can be
Straightness
Flatness
Roundness
Cylindricity
www.tankonyvtar.hu

Balzs Mik, U

10. Engineering drawing in CAD environment

285

Profile of any line

Profile of any surface

The tolerance of position can be

Parallelism
Perpendicularity
Angularity
Position
Concentricity and coaxiality
Symmetry
Run-out
In case of tolerance of position, a datum feature has to defined. The value of the tolerances
is added in millimetre.

Balzs Mik, U

www.tankonyvtar.hu

286

CAD Book

The pictures show examples to application of these tolerances.

www.tankonyvtar.hu

Balzs Mik, U

10. Engineering drawing in CAD environment

287

Surface roughness

It is not possible to achieve in practice, a geometrically ideal surface of a component and

hence, production drawings of components must also contain information about the
permissible surface conditions. Machine components which have undergone machining
operation, when inspected under magnification, will have some minute irregularities. The
actual surface condition will depend upon the finishing process adopted.
The properties and performance of machine components are affected by the degree of
roughness of the various surfaces. The higher the smoothness of the surface, the better is
the fatigue strength and corrosion resistance. Friction between mating parts is also reduced
due to better surface finish.
A surface texture specified,

As may be obtained by any production method.

As must be obtained by removal of material by machining.

As must be obtained without removal of material.

Balzs Mik, U

www.tankonyvtar.hu

288

CAD Book

Surface roughness

The surface roughness is evaluated by the height, Rt and mean roughness index Ra of the
micro-irregularities. Following are the definitions of the terms indicated in figure.
Af - It is the profile of the actual surface obtained by finishing operation.
Rf - It is the profile to which the irregularities of the surface are referred to. It passes through
the
highest point of the actual profile.
Df - It is the profile, parallel to the reference profile. It passes through the lowest point B of
the
actual profile.
Mf - It is that profile, within the sampling length chosen (L), such that the sum of the material
filled
areas enclosed above it by the actual profile is equal to the sum of the material-void areas
enclosed below it by the profile.
Rt - It is the distance from the datum profile to the reference profile.
Ra - It is the arithmetic mean of the absolute values of the heights hi between the actual and
mean
profiles.

www.tankonyvtar.hu

Balzs Mik, U

10. Engineering drawing in CAD environment

289

Surface roughness

a Ra in m
b - manufacturing technology
c sampling lenght
d directions of lay (see table)

The value of the surface roughness in general mean Ra, but we have to write it before the
value, which is in micron.
The direction of the lays, which characterise the surface optical texture can be marked, as
the table shows. There is very important to synchronise it to the manufacturing technology.

Balzs Mik, U

www.tankonyvtar.hu

290

CAD Book

Other parameters

Over the conventional surface roughness parameters we can characterized the surface
quality by several other roughness and wave parameters, and based on scanned area we can
define several 3D surface roughness parameters.
These parameters are good for compare or classify surfaces, but generally we cant use them
in design phase, because the connection between the surface roughness parameters and the
manufacturing process parameters is not known detail.

www.tankonyvtar.hu

Balzs Mik, U

10. Engineering drawing in CAD environment

291

The different production technologies result is different surface quality, so the designer
should be consider the manufacturing viewpoints during the identification of required
surface quality. The surface quality can be modified by adjust the parameters of the
technology, but the changing possibilities are very weak.

Balzs Mik, U

www.tankonyvtar.hu

292

CAD Book

Surface roughness
Ra = 1,6 m

Plain milling

Planning

Face milling

Surface grinding

Burnishing

Cylindrical grinding

This picture shows six test parts, where the Ra parameter is same, but cause of different
machining process the surface textures are different. Sometimes the aesthetic viewpoint is
so important as the numeric value of the Ra parameter.

www.tankonyvtar.hu

Balzs Mik, U

Budapest University of
Technology and Economics

Szent Istvn
University

buda University

Typotex
Publishers

TMOP-4.1.2-08/A/KMR-0029

CAD Book
11. CAD Numerical Methods
Author: Dr. Istvn Oldal
oldal.istvan@gek.szie.hu

Istvn Oldal, SZIU

www.tankonyvtar.hu

294

CAD Book

Finite element method in engineering

practice

Design

Manufacturing
the prototype

Trial
run

Sufficient

Production

Ineligible

Model of classical production

www.tankonyvtar.hu

Istvn Oldal, SZIU

11. CAD Numerical Methods

295

Finite element aided model of

production
Sufficient

Design

FEM Simulation

Prototype
neccessary

Ineligible

Production

Yes

Manufacturing
the prototype

Trial
run

Istvn Oldal, SZIU

www.tankonyvtar.hu

296

CAD Book

Equations used in FEM

Equilibrium equations
Geometric equations
Constitution (material) equations

www.tankonyvtar.hu

Istvn Oldal, SZIU

11. CAD Numerical Methods

297

Equilibrium equations
q(r) - distributed force
s(r) - stress field tensor
y

sy
dV
q(r)

k
z

xz
zx

i
x
z
a)

Istvn Oldal, SZIU

www.tankonyvtar.hu

298

CAD Book

Equilibrium equations
s x s x
dx

sx
dx

zx zx
dz

zx
dz

yx yx

yx
dy

qx 0

yx+yx
yx
sx

zx
zx

sx
dy

zx
zx+zx
yx

dx
z

z
a)

www.tankonyvtar.hu

sx+sx
qx

Istvn Oldal, SZIU

11. CAD Numerical Methods

299

Equilibrium equations
d F qdV

d F n dA s ndA

s ndA s dV
A

0 qdV s dV
V

0 q s dV
V

s q 0

Istvn Oldal, SZIU

www.tankonyvtar.hu

300

CAD Book

Geometric equations
y

duy

Deformation:

dvx
dv

d u du i dv j dw k
u u x u y du x

0
x
x
x
dx

dvy

xy = xy +yx
xy

du y
u u x u y

0
y
y
y
dy

dvx
P
P

xy
dx

dux

duy

Angle torsion:
xy xy yx arctan

www.tankonyvtar.hu

du y dv x du y
dv x
arctan

dx
dy
dx
dy

Istvn Oldal, SZIU

11. CAD Numerical Methods

301

Geometric equations
x

u
x
y

v
y

xy yx

w
z

v u

x y

Q
uQ= u

yz zy

v w

z y

uP
dr
dr

dr
uP

Istvn Oldal, SZIU

w u
zx

x z

www.tankonyvtar.hu

302

CAD Book

Boundary conditions
p0

Kinematic boundary conditions

u u0

Dynamic boundary conditions

x
z

www.tankonyvtar.hu

p p0

s n p0

Istvn Oldal, SZIU

11. CAD Numerical Methods

303

Boundary element method

s q 0

1
u u
2

s 2G

1 E

1 2

u A u0
u

s n A p0
p

Istvn Oldal, SZIU

- Equilibrium equation

- Geometric equation

- Constitutive equation

- Kinematic boundary conditions

- Dynamic boundary conditions

www.tankonyvtar.hu

304

CAD Book

Kinematically admissible
displacement field

1
u u

1 E
1 2

s 2G

www.tankonyvtar.hu

Istvn Oldal, SZIU

11. CAD Numerical Methods

305

Principle of Lagrange variation

Minimum total potential energy
u U u Wk u

Kinematic boundary:

u A 0
u

The condition of the extrema is:

Istvn Oldal, SZIU

U Wk 0

www.tankonyvtar.hu

306

CAD Book

Statically admissible stress field

Stress field is admissible if:
Satisfies the dynamic boundary conditions:
s n

Satisfies the equilibrium equations:

s q 0

www.tankonyvtar.hu

s1E
s
2G
1

Deformation field

Istvn Oldal, SZIU

11. CAD Numerical Methods

307

Elasticity problem
Given data:

Solution:

The geometry of the body

The material constants of
the body
Loads
Constraints
y

p0
V
q
P

u0
Au

dividing to elements
elements connects by
the nodes
stress- and deformation
field can be derived
nodal displacement
field

Demanded
functions:

Istvn Oldal, SZIU

u r r s r

www.tankonyvtar.hu

308

CAD Book

Approximate displacement field

Discretization, finite element

uei
u ei vei
wei
uei
v
ei u
wei ei
u ej

ue

uen
u en
ven
w
en

N eixx r N eixy r N eixz r uei

u ei r N ei r u ei N eiyx r N eiyy r N eiyz r vei

N eizx r N eizy r N eizz r wei

www.tankonyvtar.hu

Istvn Oldal, SZIU

Budapest University of
Technology and Economics

Szent Istvn
University

buda University

Typotex
Publishers

TMOP-4.1.2-08/A/KMR-0029

CAD Book
12. Application of Finite Element Method
Author: Dr. Istvn Oldal
oldal.istvan@gek.szie.hu

Istvn Oldal, SZIU

www.tankonyvtar.hu

310

CAD Book

Beam with circular cross section

1D model and its mesh

3D model and its mesh

www.tankonyvtar.hu

Istvn Oldal, SZIU

12. Application of Finite Element Method

311

Result comparison
1D model

Exact solution:
s

M h 32 F l 32 1200 N 1000mm

97,78MPa
K
d 3
503 mm3

3D model

Istvn Oldal, SZIU

www.tankonyvtar.hu

312

CAD Book

Modeling of thin-valled beams

Geometric model of beam with its constraints and loads

www.tankonyvtar.hu

Istvn Oldal, SZIU

12. Application of Finite Element Method

313

Modeling of thin-valled beams

1D, 2D and 3D finite element models

Istvn Oldal, SZIU

www.tankonyvtar.hu

314

CAD Book

Modeling of thin-valled beams

Exact solution:

Mh
6 F l a
6 1200 N 1000mm 60mm
e 4

76,48MPa
4
Iz
604 mm4 524 mm4
a a 2v

Calculated stresses of 1D, 2D and 3D models in MPa

www.tankonyvtar.hu

Istvn Oldal, SZIU

12. Application of Finite Element Method

315

Modeling of thin-walled open cross

section beams
Examined U section: 100x100x4 mm
Section length: 1000 mm
Load force:
1200 N

Maximal calculated stress:

Istvn Oldal, SZIU

Mh
1200 N 1000mm
e
50mm 28,52MPa
Iz
2103829mm4

www.tankonyvtar.hu

316

CAD Book

Modeling of thin-walled open cross

section beams

Geometric model of beam with its constraints and loads

www.tankonyvtar.hu

Istvn Oldal, SZIU

12. Application of Finite Element Method

317

Modeling of thin-walled open cross

section beams

20 elements
41 nodes

375 elements
1206 nodes

420 elements
3148 nodes

1D, 2D and 3D finite element models

Istvn Oldal, SZIU

www.tankonyvtar.hu

318

CAD Book

Modeling of thin-walled open cross

section beams

20 elements
41 nodes

375 elements
1206 nodes

420 elements
3148 nodes

1D, 2D and 3D finite element models

www.tankonyvtar.hu

Istvn Oldal, SZIU

12. Application of Finite Element Method

319

Modeling of thick-walled cylinders,

tubes
Analytical model
s
[Mpa]

r

rb

Relative reciprocative radius, where:

sk
C
0,25

srk=-pk=0

r: the radius of the tube (variable)

rb: the internal radius of the tube

Istvn Oldal, SZIU

srb=-pb=-30

www.tankonyvtar.hu

320

CAD Book

Modeling of thick-walled cylinders,

tubes

Finite element models

Short segment

www.tankonyvtar.hu

One fourth of cross

section

Longitudinal section

Istvn Oldal, SZIU

12. Application of Finite Element Method

321

Modeling of thick-walled cylinders,

tubes

Tangential stresses calculated by 3D, 2D planar and 2D axis-symmetric models

Istvn Oldal, SZIU

www.tankonyvtar.hu

Budapest University of
Technology and Economics

Szent Istvn
University

buda University

Typotex
Publishers

TMOP-4.1.2-08/A/KMR-0029

CNC machining
centre

CAD model

CAM process
Manufacturing
CNC
program

The importance of the development can be seen in case of machining.

The complicated product geometry needs advanced CAD modelling techniques, but the
manufacturing required a CNC machine. The CNC program for the manufacturing is created
by the CAM system.
The prime mover of the development is the costumer requirement. The complicate part
geometry needs CNC machining, the CNC machining needs CNC program, which can be
generated by CAM system, but the CAM systems needs the accurate CAD model.

Balzs Mik, U

www.tankonyvtar.hu

326

CAD Book

CAx elements

The figure shows the connection of the different CAx technologies.

The first stage is the computer aided conceptual design (CACD), which help to collect and
draw up the beginning requirements, design concepts and ideas. The computer aided design
(CAD) system ensure a tool for create a detail product models and drawings. The computer
aided engineering (CAE) systems support the design process with lot of different simulation
and computation solutions. Based on the CAD models the CAM (computer aided
manufacturing) systems can design the cutting tool path and NC programs for the
production. The connection between the CAD and CAM systems is the computer aided
process planning (CAPP), the task of the CAPP is to identify the steps of manufacturing
process and define all details of it. The manufacturing process has a close connection to the
computer aided quality control (CAQC), which means primary the support of coordinate
measuring technique. The manufacturing requirement planning, the scheduling of
production process are the essential elements of the production management, which are
supported by computer aided production planning and scheduling (CAPPS). The logistic tasks
can be designed by the help of computer aided storage and transportation (CAST) system.

www.tankonyvtar.hu

Balzs Mik, U

13. Integration of CAx systems

327

Increasing integrity
CE - Concurrent Engineering
CIM Computer Integrated Manufacturing
PLM Product Lifecycle Management

The integration of CAx system has different levels and these levels has an evolution.
Concurrent engineering (CE) is a work methodology based on the parallelization of tasks. It
refers to an approach used in product development in which functions of design engineering,
manufacturing engineering and other functions are integrated to reduce the elapsed time
required to bring a new product to the market.
Computer-integrated manufacturing (CIM) is the manufacturing approach of using
computers to control the entire production process. This integration allows individual
processes to exchange information with each other and initiate actions. Through the
integration of computers, manufacturing can be faster and less error-prone, although the
main advantage is the ability to create automated manufacturing processes. In a CIM system
functional areas such as design, analysis, planning, purchasing, cost accounting, inventory
control, and distribution are linked through the computer with factory floor functions such as
materials handling and management, providing direct control and monitoring of all the
operations.
Product lifecycle management (PLM) is the process of managing the entire lifecycle of a
product from its conception, through design and manufacture, to service and disposal. PLM
Balzs Mik, U

www.tankonyvtar.hu

328

CAD Book

integrates people, data, processes and business systems and provides a product information
backbone for companies and their extended enterprise. PLM describes the engineering
aspect of a product, from managing descriptions and properties of a product through its
development and useful life. The core of PLM (product lifecycle management) is in the
creations and central management of all product data and the technology used to access this
information and knowledge.

www.tankonyvtar.hu

Balzs Mik, U

13. Integration of CAx systems

329

13.2 INTEGRATION OF CAX

SYSTEMS

The CAx integration has two way:

Some CAD function build up to other applications,
CAD systems integrate other systems.

Balzs Mik, U

www.tankonyvtar.hu

330

CAD Book

Graphic kernels
CAx system

Kernel

CAx system 2

GUI

CAx system 3

During the evolution of the CAD systems the development of the graphic kernel, which
perform all calculation tasks, and the development of user interface are divided. This idea
ensures the independent development of the mathematical methods and the GUI design.
The tasks of the graphic kernel are:
Display and manage the 3D objects,
Communication inside the system,
Communication with other applications.
The development of a graphic CAD kernel is a very complicated and expensive task. Lot of
CAx applications need a limited service of a CAD system, but the integration of a complete
CAD system is impossible and mindless, so graphic kernels became commercial products.
The typical application of the graphic kernels are :
CNC simulation,
Design application,
Simulation (visualisation of the results),
Preview module of PLM system,
CAD model converter software.
www.tankonyvtar.hu

Balzs Mik, U

13. Integration of CAx systems

331

3D graphic kernels
ACIS:
Spiral Corporation (Dassault Systemes, CATIA)
Wire frame, surface and solid modelling
Functions: 3D modelling, managing and display
1989. v1. 2010. v21.
OP sys: Windows, Apple OS, SunSolaris, Linux
Extension: .SAT

The ACIS kernel is the property of Spiral Corporation, which is the part of the Dassault
Systemes. The kernel is developed in object oriented C++ environment. The ACIS support the
hybrid application of the wireframe, the surface and the solid models.
The first version was published in 1989, and in 2010 the 21st version was published. The
kernel is developed for Windows, Apple OS, SunSolaris and Linux operation systems. It has
three part: 3D modelling, managing the models and display the 3D models.
The extension of the kernel is .SAT.

Balzs Mik, U

www.tankonyvtar.hu

332

CAD Book

3D graphic kernels
Parasolid:
ShapeData (Siemens PLM (former UGS), NX)
3D surface and solid
2D object set is weak
Extension: .X_T

The Parasolid kernel is the property of Siemens PLM (former UG).

It support the hybrid surface and solid modelling.
The ability for 2D representation is weak.
The extension of the kernel is .X_T.

www.tankonyvtar.hu

Balzs Mik, U

13. Integration of CAx systems

333

CAD book - 13. Integration of CAx systems - TMOP-4.1.208/A/KMR-0029

This picture shows the list of CAx application, which use Parasolid kernel. The list contains
CAD, CAM, CAE, data exchange and other applications.

Balzs Mik, U

www.tankonyvtar.hu

334

CAD Book

3D graphic kernels
Granite:

PTC (Pro/Engineer)
3D surface and solid
Op. Sys: Windows, SunSolaris, Linux
Extension: .G

The Granite kernel is the property of PTC. The kernel is developed for Windows, SunSolaris
and Linux operation systems.
It support the hybrid surface and solid modelling.
The extension of the kernel is .G.

www.tankonyvtar.hu

Balzs Mik, U

13. Integration of CAx systems

335

Origin of the special moduls

Inner development based on users requirement
Fully integration of an independent software tool

There is 3 levels of the integration of CAx application:

The first, when independent software solutions work separately. This is a very low level
cooperation, it was typical in 70s and 80s. The communication between the software was
performed by different file formats. The results were displayed in the CAD system.
The next step was the integrated independent software solution, were the communication is
automatic, but the executed software has different user interface, and in general this
software has an independent developer.
The third way, when the user can use a fully integrated special module. In that case there is a
same user interface, and same distributor. The communication is automatic, the user just
starts the special application in the menu system.
The special modules can be born in two ways.
If a large user (like automotive of airplane company) has a special request, the CAD company
develops a special module. If it is a successful and usefull, and there is a demand from other
users it will become a commercial module.
The other way, when the user demand exists, but the developer found an existing software
solution. In that case the bigger company licences the software and integrates or buys the
smaller company, and they unite.
Balzs Mik, U

www.tankonyvtar.hu

336

CAD Book

Special CAx moduls

Conceptional design

Casting / moulding

Shoe design

Shape design

Mould design

Printed circuit design

Sheet metal part

design

Die design

Ergonomic analisys

Cable design

Sheet metal
processing

Airplane design

Pipeline design

Welding process

Automotive design

Kinematic simulation

Coordinate measure
machine

Dinamic simulation
Static simulation

Let us see some typical special CAx modules.

The tables contains some interesting application, like the shoe design, but the sheet metal
part design module or the mould design module are a very wide range used modules.

www.tankonyvtar.hu

Balzs Mik, U

13. Integration of CAx systems

337

Special CAx modules

The slide shows some pictures about the listed modules from CATIA v5 integrated CAD
system.
The advantages of special modules are the next:
Associative model
Familiar user interface
Easy communication and data exchange
Common product support
The disadvantages of special modules are the next:
Lower functionalities

Balzs Mik, U

www.tankonyvtar.hu

338

CAD Book

13.3 DATA EXCHANGE

Objects are identified by numerical code (from 1 to 5000)

Three type of the objects:
Geometrical objects
Annotation
Structural information

The Initial Graphics Exchange Specification (IGES) defines a neutral data format that allows
the digital exchange of information among Computer-aided design (CAD) systems. The
official title of IGES is Digital Representation for Communication of Product Definition Data,
first published in January, 1980 by the U.S. National Bureau of Standards as NBSIR 80-1978.
Many documents referred to it as ASME Y14.26M, the designation of the ANSI committee
that approved IGES Version 1.0.
Using IGES, a CAD user can exchange product data models in the form of circuit diagrams,
wireframe, freeform surface or solid modeling representations. Applications supported by
IGES include traditional engineering drawings, models for analysis, and other manufacturing
functions.
The IGES project was started in 1979 by a group of CAD users and vendors, including Boeing,
General Electric, Xerox, Computervision and Applicon, with the support of the National
Bureau of Standards (now known as NIST) and the U.S. Department of Defense (DoD). The
name was carefully chosen to avoid any suggestion of a database standard that would
compete with the proprietary databases then used by the different CAD vendors.
Since 1988, the DoD has required that all digital Product Manufacturing Information (PMI)
for weapons systems contracts (the engineering drawings, circuit diagrams, etc.) be delivered
www.tankonyvtar.hu

Balzs Mik, U

13. Integration of CAx systems

343

in electronic form, specifically in IGES format. As a consequence, any CAx software vendor
who wants to market their product to DoD subcontractors and their partners must support
the import (reading) and export (writing) of IGES format files.
An ANSI standard since 1980, IGES has generated enough data to fill warehouses full of
magnetic tapes and CD-ROMs of digital PMI for the automotive, aerospace, and shipbuilding
industries, as well as for weapons systems from Trident missile guidance systems to entire
aircraft carriers. These part models may have to be used years after the vendor of the
original design system has gone out of business. IGES files provide a way to access this data
decades from now. Today, plugin viewers for Web browsers allow IGES files created 20 years
ago to be viewed from anywhere in the world.
After the initial release of STEP (ISO 10303) in 1994, interest in further development of IGES
declined, and Version 5.3 (1996) was the last published standard. A decade later, STEP has
yet to fulfill its promise of replacing IGES, which remains the most widely used standard for
CAx and PMI interoperability.

Balzs Mik, U

www.tankonyvtar.hu

344

CAD Book

IGES geometry objects (entities)

Curves
100 circular arc
102 composite curve
110 line
112 parametric spline
126 rational B-spline
curve
Surfaces
108 plane
114 spline
118 ruled surface
120 revolve surface
128 rational B-spline
surface

Solids
150 block
154 cylinder
156 cone
158 sphere
160 torus
161 revolve solid
502 vertex
504 edge
508 loop
510 face
514 shell

Other
124 transformation
matrix
132 connect point
136 finite element
entity

An IGES file is composed of 80-character ASCII records, a record length derived from the
punched card era. Text strings are represented in "Hollerith" format, the number of
characters in the string, followed by the letter "H", followed by the text string, e.g., "4HSLOT"
(this is the text string format used in early versions of the Fortran language). Early IGES
translators had problems with IBM mainframe computers because the mainframes used
EBCDIC encoding for text, and some EBCDIC-ASCII translators would either substitute the
wrong character, or improperly set the Parity bit, causing a misread.
The file is divided into 5 Sections, indicated by a character (S, G, D, P, or T) in column 73. The
characteristics and geometric information for an entity is split between two sections; one in
a two record, fixed-length format (the Directory Entry, or DE Section), the other in a multiple
record, comma delimited format (the Parameter Data, or PD Section), as can be seen in a
more human-readable representation of the file.
The pictures show some typical geometric and other entities.

www.tankonyvtar.hu

Balzs Mik, U

13. Integration of CAx systems

345

IGES objects (entities)

Annotation entities
206 diameter dimension
212 general note
216 linear dimension
220 point dimension
222 radius dimension
230 sectioned area

Balzs Mik, U

Structure entities
302 associativity definition
310 text font definition
314 colour definition
404 drawing entity
410 view entity
412 rectangular array
subfigure
414 circular array subfigure

www.tankonyvtar.hu

13. Integration of CAx systems

351

50 sphere
ProE WF4 STL

If the export the previous sphere to STL format and reopen it, the triangles can be seen. The
dimension of the triangles can be adjusted, and we can improve the surface quality of the
model.

Balzs Mik, U

www.tankonyvtar.hu

352

CAD Book

The diagram shows the size of the model of the sphere in case of different file formats in
logarithmic scale.
The original model was created in ProEngineer WF4. The size of the file is about 82 kB. The
VDA representation is about 1MB, this is the largest version. The smallest file was the kernel
format (ASIC and Parasolid). The STL files size depends on the density of the corner points
of the triangles.
The IGES and STEP files have more then 10 times smaller size, than the original model.

www.tankonyvtar.hu

Balzs Mik, U

13. Integration of CAx systems

353

Synchronous modelling

The synchronous modelling is the patented technology of Siemens PLM (NX, Solid Edge)
since 2008.
It works on Parasolid kernel, and it ensure the parametric modification of a non parametric
model and the direct modelling without sketches, and there is no model history. This
technology correct the defects of manipulation of neutral models.

Balzs Mik, U

www.tankonyvtar.hu

354

CAD Book

13.4 CAD LIBRARIES

www.tankonyvtar.hu

Balzs Mik, U

13. Integration of CAx systems

355

CAD libraries
Standard parts, integrated user interface

Supplier specific off-line

catalogue
Integrated
Not-integrated

Supplier specific on-line

catalogue
Sometimes registration
required

During the engineering design shall be sought to reduce the own designed parts. The aim of
this rule is to increase the productivity of the design process, and rationalize the
manufacturing and assembly. The reused components can be standard parts, like screws or
commercial components, like bearings, motors, hydraulic or pneumatic components etc.
The productivity of the design process can be further increased by use of electronic
catalogues and the product will be build up from downloaded components.
This catalogues or libraries can be an integrated component of a CAD system, with the
common user interface, and in general they contain standard elements.
If we need a special part or component, we have to use the supplier specific catalogues,
because we will order this part from the selected company and we need the accurate model
of the element.
The catalogue can be an off-line catalogue, which have to be installed to the computer, and it
can be an integrated with the CAD system, or stand alone.
The other possibilities is the on-line catalogue, which can be use via internet and dont need
installation. In that case the database is up-to-date, but without internet it cant be used, and
sometimes the use of it needs registration.

Balzs Mik, U

www.tankonyvtar.hu

356

CAD Book

The picture shows an example from the Meusburger mould component catalogue.
After the selection of the required plate, the 3D model can be downloaded and open in a
CAD system. As the model tree shows, the structure and the features of the model cannot
see, the 3D model consists of only one feature. The model is not parametric.

www.tankonyvtar.hu

Balzs Mik, U

13. Integration of CAx systems

357

OP
OP

These robot grippers were designed for handling of plastic parts.

The number of original parts (OP) is very low, because lot of elements can be find in
suppliers digital catalogues, and the downloaded 3D CAD model were assembled to the
product.

Balzs Mik, U

www.tankonyvtar.hu

358

CAD Book

13.5 DIGITAL MOCK-UP

www.tankonyvtar.hu

Balzs Mik, U

13. Integration of CAx systems

359

Digital mock-up definition

Digital mock-up (DMU) is a concept that allows the description of a product, usually in 3D,
for its entire life cycle. Digital mock-up is enriched by all the activities that contribute to
describing the product.
The product design engineers, the manufacturing engineers, and the support engineers work
together to create and manage the DMU. One of the objectives is to have an important
knowledge of the future or the supported product to replace any physical prototypes with
virtual ones, using CAx techniques. As an extension it is also frequently referred to as Digital
Prototyping or Virtual Prototyping. These two specific definitions refer to the production of a
physical prototype, but they are part of the DMU concept.
DMU allows engineers to design and configure complex products and validate their designs
without ever needing to build a physical model.

Balzs Mik, U

www.tankonyvtar.hu

360

CAD Book

Goal of DMU
Reduce time-to-market
Reduce product development costs
Increase product quality

The main goal and advantages of the using of digital mock-up is the next:
Reduce time-to-market by identifying potential issues earlier in the design process.
Reduce product development costs by minimizing the number of physical prototypes that
need to be built.
Increase product quality by allowing a greater number of design alternatives to be
investigated before a final one is chosen.
Digital mock-up not only reduces the time A&D manufacturers need to develop and validate
the product, it also offers more much flexibility in evolving the product design. Moreover,
digital mock-up is perfectly suited for the virtual product development environment in which
the OEMs and globally dispersed suppliers and partners must collaborate.

www.tankonyvtar.hu

Balzs Mik, U

13. Integration of CAx systems

361

Possible simulation

Photorealistic visualisation
Motion analysis
Collision analysis
Tolerance analysis
FEM (Static, Dynamic , Flow,
Magnetic, Heat )
Ergonomic analysis
DfX analysis
Manufacturing simulation
(cutting, casting, moulding,
forming)
Virtual crash test

The digital mock-up ensures to perform several analysis, which were mentioned previously.
These analysis are not essential part of the digital mock-up, it only ensures the possibilities
for it by all required data.

Balzs Mik, U

375

Product model and information management

Attila Piros, BUT

www.tankonyvtar.hu

376

CAD Book

Product model and information management

DataBase Management System (DBMS)
DBMS is a software system providing access for the databases and
containing various service functions. The fundamental functions of a
DBMS are the following:
indexing: a method for increasing the speed of data search
supporting transactions: controlled manipulating of several data in
the same time
replication: continuous synchronizing of more database instances,
automatic switching in case of the error of the primary database
security functions: support of the encryption, user access rights and
logging the activities
locking: DBMS locks the related data until a transaction is
successfully closed

www.tankonyvtar.hu

Attila Piros, BUT

14. PDM/PLM systems

377

Product model and information management

The additional functions of a DBMS are the following:
query ability: supporting the complex, sometimes nested queries

backup and replication: supporting the unified database structures

even in case of far geographical locations
rule enforcement: decreasing the errors caused by manual input
advanced security: controlling the data access, remove functions
both on user and user group levels
change and access logging: tracking the data manipulation
automated optimization: statistically based automated setup
procedure to increase the performance of the DBMS

Attila Piros, BUT

www.tankonyvtar.hu

378

CAD Book

Product Database Management (PDM)

PDM systems provide the structural storage for all the product related
data. The main functions of the PDM systems are the following:
heterogeneous data handling: storage of heterogeneous product
data (CAD files, Office documents, e-mails, etc.)
quick information search: in case of any product data
visualization: displaying the up to date CAD data (previews,
exploded views, etc.)
product structure handling: displaying and exporting the product
structures in customizable formats (Bill of Material (BOM) lists)

www.tankonyvtar.hu

Attila Piros, BUT

14. PDM/PLM systems

379

392

CAD Book

15.1 3D SCANNING

www.tankonyvtar.hu

Balzs Mik, Richrd Horvth, U

15. Peripheral technologies

3D scanning
CAD reproduction of a part
Based on real part
Process:

Scanning (digitalizing)
Point cloud manipulation
CAD modelling, reconstruction
Verification

393

Real part

Point cloud

3D CAD model

Methods of scanning:
Contact
Non-contact

The aim of the 3D scanning is to digitalized a real part for additional CAx work. We use this
methods, if there is no CAD documentation, no drawing documentation, or the shape of the
part is too complicated to remodelling.
The scanning process consist of the next steps:
Digitalizing of the shape by scanning machine,
Manipulation of the point cloud, correct and smooth the points,
Create 3D surfaces based on point cloud,
Verification the surface, check the accuracy and correctness of the part.
For the scanning two type of machines can be applied: the contact and the non contact
method.

Balzs Mik, Richrd Horvth, U

www.tankonyvtar.hu

394

CAD Book

Contact scanning methods

CMM
Rigid
Accurate
Programable

Measuring arm
Flexible
Mobile
Manual

In case of contact method we use a coordinate measuring machine (CMM) or the measuring
arm. These machines are the tools of geometrical measurement, but they are able to
generate the appropriate data.
The CMM has a very rigid design, therefore the accuracy is high. The CMM in general a
programmable device, so it is able to perform an automatic scanning, which is a big
advantage, if we would like to create a dense point cloud.
The measuring arm is very flexible, we can use it in case of complicated parts. It is a mobile
device, so we can digitalize a large parts however inside the laboratory. The measuring arm is
manual use.

www.tankonyvtar.hu

Balzs Mik, Richrd Horvth, U

15. Peripheral technologies

395

Contact scanning methods

Touch-trigger head

Accurate
Small contact force
Slow process
Not expensive

Analogue head

Accurate
Larger contact force
Fast process
High density of points

In case of use of coordinate measuring machine two type of head can be used.
The first is the touch-trigger head, which is very accurate, has a small contact force, but the
scanning process is slow, because we have to touch the surface point by point. These devices
are not too expensive.
The other type is the analogue head, which is accurate too, but in that case there is a larger
contact force, because it can performed an automatic continuous scanning. The scanning
process is faster and the density of the points will be high.

Balzs Mik, Richrd Horvth, U

www.tankonyvtar.hu

396

CAD Book

Non-contact scanning
No contact force
Good for soft materials
LASER scanning
Reflection problems

CCD scanning
Expensive
Mobile

The second type of scanning methods is the non-contact method. There are no contact force,
so we can scan soft materials too (like PU foam part).
For the scanning we can use laser beam. The reflection of the part can be problematic,
therefore sometimes the surface need some preparation. In case of undercutted surfaces,
we have to create and fit several point cloud patch.
The CCD camera based devices are portable, ensure very fast scanning, but very expensive.

www.tankonyvtar.hu

Balzs Mik, Richrd Horvth, U

15. Peripheral technologies

397

15.2 RAPID PROTOTYPING

Balzs Mik, Richrd Horvth, U

www.tankonyvtar.hu

398

CAD Book

Role of rapid prototyping

Presentation
Pattern for casting
Rapid tooling
Rapid production

Rapid prototyping is the automatic construction of physical objects using additive

manufacturing technology based on CAD model.
The aim of rapid prototyping methods is to create a prototype part directly from the CAD
model in shorter time like in case of conventional methods.
These prototypes are suitable for presentation, we can use them as pattern for sand casting,
the prototype can be a tool, mould or die, so we can use as production equipments, or in
some case the prototype equal the final part, so we can use the RP methods for production.
The word "rapid" is relative: construction of a model with contemporary methods can take
from several hours to several days, depending on the method used and the size and
complexity of the model. Additive systems for rapid prototyping can typically produce
models in a few hours, although it can vary widely depending on the type of machine being
used and the size and number of models being produced simultaneously.

www.tankonyvtar.hu

Balzs Mik, Richrd Horvth, U

15. Peripheral technologies

399

Application fields

The rapid prototyping has a great role in automotive industry and consumer products
development, because the use of RP reduce the time and cost of development.

Balzs Mik, Richrd Horvth, U

www.tankonyvtar.hu

400

CAD Book

General process

CAD model

Slicing

Prototyping

Prototype

automatic construction of physical objects

additive manufacturing technology
based on CAD model.

With additive manufacturing, the machine reads in data from a CAD drawing and lays down
successive layers of liquid, powder, or sheet material, and in this way builds up the model
from a series of cross sections. These layers, which correspond to the virtual cross section
from the CAD model, are joined together or fused automatically to create the final shape.
The primary advantage to additive fabrication is its ability to create almost any shape or
geometric feature.

www.tankonyvtar.hu

Balzs Mik, Richrd Horvth, U

15. Peripheral technologies

401

RP Technologies
RP technologies

Powder

Sheet

Liquid

1 component

Melting

Gluing

1 component
+ glue

Polimerization
Polimerization

Light

Heat

The methods classified by the type of raw material. The raw material can be a powder, and
they will unite by melting or glue. We can use liquid raw material with polymerization or
melting. The polymerization can catalyze with light or heat. Some methods use sheets
typically by gluing.
Lets see the details of these technologies.
The most known RP technologies are the follows:
SLA Stereolithography
SLS Selective laser sintering
LOM Laminated object manufacturing
FDM Fused deposition modelling
3DP 3D printing
PolyJet
SGC Solid ground curing

Balzs Mik, Richrd Horvth, U

www.tankonyvtar.hu

402

CAD Book

SLA - Stereolithography
Scenner system

Laser

Layers of
solidify resin

Layer thickness: 0,1 mm

UV post processing required
Strength: 30 MPa
PBT, PA, PP, PC

Liquid resin

Platform

Stereolithography is an additive manufacturing process using a vat of liquid UV-curable

photopolymer resin and a UV laser to build parts a layer at a time. On each layer, the laser
beam traces a part cross-section pattern on the surface of the liquid resin. Exposure to the
UV laser light cures, solidifies the pattern traced on the resin and adheres it to the layer
below.
After a pattern has been traced, the SLA's elevator platform descends by a single layer
thickness, typically 0.05 mm to 0.15 mm. Then, a resin-filled blade sweeps across the part
cross section, re-coating it with fresh material. On this new liquid surface, the subsequent
layer pattern is traced, adhering to the previous layer. A complete 3-D part is formed by this
process. After building, parts are cleaned of excess resin by immersion in a chemical bath
and then cured in a UV oven.
Stereolithography requires the use of support structures to attach the part to the elevator
platform and to prevent certain geometry from not only deflecting due to gravity, but to also
accurately hold the 2-D cross sections in place such that they resist lateral pressure from the
re-coater blade. Supports are generated automatically during the preparation of 3-D CAD
models for use on the stereolithography machine, although they may be manipulated
manually. Supports must be removed from the finished product manually.
www.tankonyvtar.hu

Balzs Mik, Richrd Horvth, U

15. Peripheral technologies

403

SLS Selective laser sintering

Wide variety of build
material (plastic and
metal)
No support material
No post processing
Multiple part building
High strength
Thin wall
Small parts
Porous part

Laser

Roller

Scenner system

Powder

Platform

Selective laser sintering (SLS) is an additive manufacturing technique that uses a high power
laser (for example, a carbon dioxide laser) to fuse small particles of plastic, metal (direct
metal laser sintering), ceramic, or glass powders into a mass that has a desired 3-dimensional
shape. The laser selectively fuses powdered material by scanning cross-sections generated
from a 3-D digital description of the part (for example from a CAD file or scan data) on the
surface of a powder bed. After each cross-section is scanned, the powder bed is lowered by
one layer thickness, a new layer of material is applied on top, and the process is repeated
until the part is completed.
Because finished part density depends on peak laser power, rather than laser duration, a SLS
machine typically uses a pulsed laser. The SLS machine preheats the bulk powder material in
the powder bed somewhat below its melting point, to make it easier for the laser to raise the
temperature of the selected regions the rest of the way to the melting point.
Some SLS machines use single-component powder, such as direct metal laser sintering.
However, most SLS machines use two-component powders, typically either coated powder or
a powder mixture. In single-component powders, the laser melts only the outer surface of
the particles (surface melting), fusing the solid non-melted cores to each other and to the
previous layer.
Balzs Mik, Richrd Horvth, U

www.tankonyvtar.hu

404

CAD Book

Compared to other methods of additive manufacturing, SLS can produce parts from a
relatively wide range of commercially available powder materials. These include polymers
such as nylon, (neat, glass-filled or with other fillers) or polystyrene, metals including steel,
titanium, alloy mixtures, and composites and green sand. The physical process can be full
melting, partial melting, or liquid-phase sintering. And, depending on the material, up to
100% density can be achieved with material properties comparable to those from
conventional manufacturing methods. In many cases large numbers of parts can be packed
within the powder bed, allowing very high productivity.

www.tankonyvtar.hu

Balzs Mik, Richrd Horvth, U

15. Peripheral technologies

405

LOM Laminated object manufacturing

Scenner system

Laser

Laminating
roll

Paper model (thickness 0,1 mm)

Cut by laser and laminate
Painable
Close cavity is impoossible

Paper roll
Platform

Laminated object manufacturing (LOM) is a rapid prototyping system developed by Helisys

Inc. In it, layers of adhesive-coated paper, plastic, or metal laminates are successively glued
together and cut to shape with a knife or laser cutter.
The process is performed as follows:
1.Sheet is adhered to a substrate with a heated roller.
2.Laser traces desired dimensions of prototype.
3.Laser cross hatches non-part area to facilitate waste removal.
4.Platform with completed layer moves down out of the way.
5.Fresh sheet of material is rolled into position.
6.Platform moves up into position to receive next layer.
7.The process is repeated.
The most important properties of LOM:
Low cost due to readily available raw material
Paper models have wood like characteristics, and may be worked and finished
accordingly

Balzs Mik, Richrd Horvth, U

www.tankonyvtar.hu

406

CAD Book

Dimensional accuracy is slightly less than that of Stereolithography and Selective laser
sintering but no milling step is necessary.
Relatively large parts may be made, because no chemical reaction is necessary.

www.tankonyvtar.hu

Balzs Mik, Richrd Horvth, U

15. Peripheral technologies

407

FDM Fused deposition modeling

ABS plastic wire

Layer thickness: 0,2 mm
No post processing
Paintable, glueable
Automatic support material
processing
Model
material

Melting head
Model
material
Support
material

Platform

Support
material

Fused deposition modelling (FDM) is an additive manufacturing technology commonly used

for modelling, prototyping, and production applications. The technology was developed by S.
Scott Crump in the late 1980s and was commercialized in 1990. FDM begins with a software
process, developed by Stratasys, which processes an STL file (stereolithography file format) in
minutes, mathematically slicing and orienting the model for the build process. If required,
support structures are automatically generated. The machine dispenses two materials one
for the model and one for a disposable support structure.
FDM, a prominent form of rapid prototyping, is used for prototyping and rapid
manufacturing. Rapid prototyping facilitates iterative testing, and for very short runs, rapid
manufacturing can be a relatively inexpensive alternative.
Several materials are available with different trade-offs between strength and temperature
properties. As well as acrylonitrile butadiene styrene (ABS) polymer, polycarbonates (PC),
polycaprolactone (PCL), polyphenylsulfones (PS) and waxes.
The thermoplastics are liquefied and deposited by an extrusion head, which follows a toolpath defined by the CAD file. The materials are deposited in layers as fine as 0.125 mm
(0.005") thick, and the part is built from the bottom up one layer at a time.

Balzs Mik, Richrd Horvth, U

www.tankonyvtar.hu

408

CAD Book

3DP 3D printing
Glue head

Powder and glue

Colour model
Tempering post processing
required

Roller

Powder

Platform

3D printing is a form of additive manufacturing technology where a three dimensional object

is created by laying down successive layers of material. 3D printers are generally faster, more
affordable and easier to use than other additive manufacturing technologies. 3D printers
offer product developers the ability to print parts and assemblies made of several materials
with different mechanical and physical properties in a single build process. Advanced 3D
printing technologies yield models that can serve as product prototypes.
The method of 3D printing consists of an inkjet printing system. The printer creates the
model one layer at a time by spreading a layer of powder (plaster, or resins) and inkjet
printing a binder in the cross-section of the part. The process is repeated until every layer is
printed. This technology is the only one that allows for the printing of full colour prototypes.
This method also allows overhangs. It is also recognized as the fastest method.

www.tankonyvtar.hu

Balzs Mik, Richrd Horvth, U

15. Peripheral technologies

409

PolyJet

Jet head
UV light

Model
material

Polymer

Ink jet printing

Direct polymer pronting
Polymer + UV
Multi component available
Layer thickness: 0.02 mm !!!

Support
material

Platform

PolyJet Matrix Technology, a new direction in 3D printing, is the first technology that
enables simultaneous jetting of different types of model materials, available on Connex
family of 3D Printing Systems.
Objets patent-pending PolyJet Matrix technology works by jetting two distinct Objet
FullCure photopolymer model materials in preset combinations.
The dual-jet process can combine materials in several ways, enabling the simultaneous use of
two different rigid materials, two flexible materials, one of each type, any combination with
transparent material, or two jets of the same material.
Each material is funneled to a dedicated liquid system connected to the PolyJet Matrix block,
which contains 8 printing heads. Two perfectly synchronized printing heads are designated
for each material, including the support material.
PolyJet Matrix Technology controls every one of the 96 nozzles in every print head. Preset
composites of model materials are jetted from designated nozzles according to location and
model type, providing full control of the structure of the jetted material and hence of its
mechanical properties. This enables each composite material, called a Digital Material, to
provide specific values for tensile strength, elongation to break, HDT and even Shore A
values.

Balzs Mik, Richrd Horvth, U

www.tankonyvtar.hu

410

CAD Book

The materials are jetted in ultra-thin layers onto a build tray, layer by layer, until the part is
completed. Each photopolymer layer is cured by UV light immediately after it is jetted,
producing fully cured models that can be handled and used immediately, without postcuring. The gel-like support material, which is specially designed to support complicated
geometries, is easily removed by hand and water jetting.
PolyJet Matrix Advantages
Enables the on-the-fly fabrication of Digital Materials Composite materials that
closely emulate the mechanical properties of the target design
Enables the combination of black and white rigid materials, creating a wide range of
greyscales suitable for consumer electronics and other applications
Eliminates the need to design, print and glue together separate model parts made with
different materials in order to create a complete model, saving printing and postprocessing time
Dramatically reduces the risk of error when creating complex moulds for double injection
by enabling the majority of testing to be performed on early stage prototypes instead of
requiring silicon moulds

www.tankonyvtar.hu

Balzs Mik, Richrd Horvth, U

15. Peripheral technologies

411

SGC Solid ground curing

Spray resin

Create photomask

Material: vax
No support material
Good surface quality

Expose mask
Vacuum uncured resin

Spray wax

Complicated
Expensive

Mill plane

Platform

Solid Ground Curing (SGC), also known as the Solider Process, is a process that was invented
and developed by Cubital Inc. of Israel. The overall process is illustrated in the figure above
and the steps are illustrated below. The SGC process uses photosensitive resin hardened in
layers as with the Stereolithography (SLA) process. However, in contrast to SLA, the SGC
process is considered a high-throughput production process. The high throughput is achieved
by hardening each layer of photosensitive resin at once. Many parts can be created at once
because of the large work space and the fact that a milling step maintains vertical accuracy.
The multi-part capability also allows quite large single parts (e.g. 500 500 350 mm / 20
20 14 in) to be fabricated. Wax replaces liquid resin in non-part areas with each layer so
that model support is ensured.
The steps in the process are as follows.
First, a CAD model of the part is created and it is sliced into layers using Cubital's Data Front
End software. At the beginning of a layer creation step, the flat work surface is sprayed
with photosensitive resin.
Next, the photomask is positioned over the work surface and a powerful UV lamp hardens
the exposed photosensitive resin.
After the layer is cured, all uncured resin is vacuumed for recycling, leaving the hardened
areas intact.
Balzs Mik, Richrd Horvth, U

www.tankonyvtar.hu

412

CAD Book

The cured layer is passed beneath a strong linear UV lamp to fully cure it and to solidify any
remnant particles.
In the fifth step, wax replaces the cavities left by vacuuming the liquid resin. The wax is
hardened by cooling to provide continuous, solid support for the model as it is fabricated.
In the final step before the next layer, the wax/resin surface is milled flat to an accurate,
reliable finish for the next layer.
Once all layers are completed, the wax is removed, and any finishing operations such as
sanding, etc. can be performed. No post-cure is necessary.

www.tankonyvtar.hu

Balzs Mik, Richrd Horvth, U

15. Peripheral technologies

413

15.3 CAM SYSTEMS

Balzs Mik, Richrd Horvth, U

www.tankonyvtar.hu

414

CAD Book

CAM system
Computer Aided Manufacturing
Tasks:
Cutting tool path design
Generation of NC program
Elements of a CAM system:
Tool path generation
Edit of tool path
Optimization of tool path
Material and tool database
Machining time calculation
NC postprocessing

The aim of the CAM systems is to connect the virtual CAD model and the real manufacturing.
The computer aided manufacturing (CAM) at first look seems a very complicated and
ambitious term, but in real it means only the design of cutting tool path and the generation
of NC program. The NC program is the alphanumerical code for control the work of CNC
controlled automatic machine tools.
In case of complex part geometry the design of cutting tool path, which will generate the
surface of the part, needs a lot of calculation, which takes lot of time. The CAM systems
perform these calculations based on CAD model.
The typical parts of a CAM system are the next:
Tool path generation
Edit of tool path
Optimization of tool path
Material and tool database
Machining time calculation
NC postprocessing

www.tankonyvtar.hu

Balzs Mik, Richrd Horvth, U

15. Peripheral technologies

415

CAM classification
Manufacturing technology
Milling
Turning
Cutting (laser, water jet, oxyfuel
cutting, plasma arc, wire-edm)
Coordinate measuring machine
Degree of freedom

The CAM systems can be classified by several viewpoints.

The first is the type of the machine tool or the applied cutting technology. So we can talk
about CAM systems for milling, turning, cutting (laser, water jet, oxyfuel cutting, plasma arc,
wire-edm) technologies or coordinate measuring.
The other classification based on the degree of freedom. The degree of freedom is the one
axis moving possibility. The degree of freedom depends the technology and the design of the
machine tool. Let us see some example.

Balzs Mik, Richrd Horvth, U

www.tankonyvtar.hu

416

CAD Book

Degree of freedom in CAM systems

Number of direction of moving possibilities
1D moving in one axis
Drilling
2D parallel moving in two axis
Turning
Cutting (laser, plasma, water, wire-edm)
2.5D machining in x-y plane + moving for
depth
Some milling operation: face milling,
roughing, z-level milling

X
Z

In case of 1D the tool has only one moving direction, like drilling.
In case of 2D the tool can move parallel in two direction. The turning and some cutting
technology is typically 2D manufacturing.
The 2.5D means, that the 2D parallel moving possibilities is completed by a 3rd step motion,
like some milling process.

www.tankonyvtar.hu

Balzs Mik, Richrd Horvth, U

15. Peripheral technologies

417

3D parallel moving in three axis

Finishing milling of free form surfaces
Coordinate measuring machine
4D
Cutting in two parallel plane (eg. wireedm)
Twin spindle lathe
5D
5D milling: 3 linear axis + 2 rotary axis
6D
Industrial robots
xD
Multi axis machine tools
(eg. Tool grinding machine)

The 3D means simultaneous moving in 3 direction. The free form CNC milling and the
coordinate measuring machine need this type of control.
The higher dimensions means complicated machine tools.
The 4D can be 2x2D, like in case of wire EDM of twin spindle late, or 4 simultaneous moving,
like 3 linear and 1 rotational, or other.
The 5D is typically means 5D milling, when the 3 linear motion is competed by 2 rotational.
The industrial robots generally has a 6D control, like a humanoid robot, which has 6 rotary
axes.
Some special machine tool required more axes.

Balzs Mik, Richrd Horvth, U

www.tankonyvtar.hu

418

CAD Book

CAM process

Open and prepare the

CAD model
Select machine tool

Modification
Blank material
Basic data, Type of CNC
controler, Coordinate system,
Safety planes

Select tool
Diameter, Length, Corner
radius, Tool holder
Select strategy
Define parameters
Define geometry
Axis, Curve, Surface, Volume,
Window
Calculation

Display tool path, Collision

check, Manufacturing time

Simulation

Generate CNC program

Create documentation

This pictures shows and summarized the typical workflow of a CAM system.
The order of the definition can be different in different CAM systems, but the definition of
the listed data is required every case for appropriate work.
The most important application of the CAM systems is the milling technology, so hereafter I
focus to this application.

www.tankonyvtar.hu

Balzs Mik, Richrd Horvth, U

15. Peripheral technologies

419

0. Manufacturing process planning

1. Open and prepare the CAD model
File formats, data loss
Native / Neutral (dxf, step, iges, vda, stl etc.)
Parametric / Model hystory / Surface bugs
Modification of the CAD geometry
Surface pathing (eg. holes)
Define blank material

The CAM workflow start with the manufacturing process planning. We have to plan the
manufacturing process, because during the CAM workflow we take only definition. The CAM
system can not create a process, can not select tool, can not define cutting parameters. The
engineer will define them.
First, the CAD model is opened in the CAM system in native or neutral formats depends on
CAM systems and consider the advantages and disadvantages. More details about data
exchange is described in 13nd chapter.
If need and possible the geometry is corrected of modified, and the blank material geometry
is defined.

Balzs Mik, Richrd Horvth, U

www.tankonyvtar.hu

420

CAD Book

2. Selection of machine tool

Basic data (workspace, limits of cutting parameters
etc.)
Type of CNC controller
Define coordinate system
Define safety planes

1
2
1 safety plane, over this plane the
3D rapid motion enabled
2 retract plane, plane of connection
motions

The second step is the machine tool selection. Here we have to define some basic data of the
machine tool, like the size of the workplace, the limits of cutting parameters. We have to
select the type of CNC controller, because it is an essential data for generate NC program.
The next step is the definition the coordinate system. The coordinate system gives the null
point of the program.
In lot of CAM system we can define 2 planes over the part. Over the safety plane the 3D
rapid motion is enabled, under it, the tool can be move fast only in perpendicular to the
plane. The retract plane defines the level of the connection motions. Sometimes these two
planes are same.

www.tankonyvtar.hu

Balzs Mik, Richrd Horvth, U

15. Peripheral technologies

3. Selection of cutting tool

Tool data base
Basic geometrical data
Diameter D
Length - L
Corner radius - R
Cutting parameters:
Material
Roughing / Finishing
n (vc), vf

421

The third step is the cutting tool selection or define. Lot of CAM systems contains a tool
database, which contains geometric descriptions of cutting tools. This database contains the
tools, which are exist in the machining workshop. The CAM system need only three
geometric parameters of cutting tools in case of milling: diameter, length and corner radius.
In general the database contains the recommended cutting data.

Balzs Mik, Richrd Horvth, U

www.tankonyvtar.hu

422

CAD Book

4. Selection of tool path strategy

Technology oriented tool path strategies
Standard strategies + CAM system oriented special
strategies
One task more strategies
Tool Part geometry Tool path strategy

Tool

Part geometry

Tool path
strategy

The most important part of a CAM system is the list of manufacturing strategies.
The tool path strategy define the character of the machining. The CAM engineer have to
select the most appropriate strategy, consider the part geometry and the cutting tool.
The CAM systems contains standard strategies and CAM system oriented special strategies.
One manufacturing task can be solved by several different ways, the CAM systems ensure lot
of tools for successful manufacturing.

www.tankonyvtar.hu

Balzs Mik, Richrd Horvth, U

15. Peripheral technologies

423

5. Selection of machined geometry

Axis, Curve, Surface, Volume
On the CAD model / Associative definition
Milling surface

Milling volume

6. Calculation of tool paths

In the next step we have to select or defined the geometry related to the selected strategy.
We can select different type of geometrical elements:
Axis for hole making,
Curve engraving, slot milling,
Surface surface milling,
Volume rough milling.
We can select the existing geometry elements of the CAD model, or we can define new
elements.
After the definition the CAM system performs the calculations. Typical it takes less the 1
minute.

Balzs Mik, Richrd Horvth, U

www.tankonyvtar.hu

424

CAD Book

7. Simulation
Display the tool path
Manufacturing simulation
Part + Tool

+ Machnie tool

+ Fixture
Coolision check

Part

Tool
Fixture
Tool holder

Other simulations
Machining time
Machining power

Machine tool

After the calculation we can control the result by simulations.

The simplest simulation is the simple display of the tool path.
The manufacturing simulation we can follow the machining process, we can see the
generated part geometry. Basically this simulation contains only the part and the tool
geometry, but we can complete the simulation with the machine tool and the fixture.
The other type of the simulation is the collision check, when the collision between the tool
and the part, the tool and the fixture or machine tool, or the tool holder and other elements
are detected.
The machining time calculation is an important type of the simulation. Some CAM systems
are able to calculate more process parameter, like machining power.
The next pictures show some example about simulation.

www.tankonyvtar.hu

Balzs Mik, Richrd Horvth, U

15. Peripheral technologies

425

CATIA v5

Simulation of turning and milling in CATIA V5 CAM system.

Balzs Mik, Richrd Horvth, U

www.tankonyvtar.hu

426

CAD Book

MSN 500 NC milling machine

buda University
machining workshop
CATIA v5

The simulation of the MSN500 NC milling machine in CATIA v5 CAM system.

www.tankonyvtar.hu

Balzs Mik, Richrd Horvth, U

15. Peripheral technologies

427

Volume milling

Pro/Engineer WF4

Machining simulation of milling of an EDM electrode in ProEngineer WF4.

The simulation shows the stepped surface after the roughing process.

Balzs Mik, Richrd Horvth, U

www.tankonyvtar.hu

428

CAD Book

Pro/Engineer WF4

Surface milling

Simulation of surface milling in ProEngineer WF4.

The tool path display shows only the path, but the simulation displays the surface quality.

www.tankonyvtar.hu

Balzs Mik, Richrd Horvth, U

15. Peripheral technologies

429

Siemens NX

Keller

Some simulation system ensure the possibilities of simulation the complete manufacturing
environment.

Balzs Mik, Richrd Horvth, U

www.tankonyvtar.hu

430

CAD Book

8. Create NC program
Independent format (APT / EXAPT)
CNC controller oriented format (postprocessing)
CAM system
Post-processor

EXAPT
CLData

#1 NC program
G code
#2 NC program
G code

#x NC program
G code

If the tool path is pass in the simulation, we can generate the NC code for machine tool.
This process consists of two step. First we create an independent general code, and during
the second step the general code is transformed to the CNC controller oriented format.
However the format of NC code is standard, the different controller use a little bit different
codes. This transformation is called postprocessing, and the software component is the
postprocessor.

www.tankonyvtar.hu

Balzs Mik, Richrd Horvth, U

15. Peripheral technologies

431

9. Documenting
Location of the coordinate system
Name of NC program
Tool data
Cutting parameters
Manufacturing time

The last step is the documenting.

The CAM documentation contains all necessary data for production:
Location of the coordinate system
Name of NC program
Tool data
Cutting parameters
Manufacturing time

Balzs Mik, Richrd Horvth, U

www.tankonyvtar.hu

Fashion Studies Notes
No ratings yet
Fashion Studies Notes
14 pages
Color List Equivalence IP - RAL
63% (19)
Color List Equivalence IP - RAL
139 pages
Optical Unconscious, by Rosalind E. Krauss
100% (13)
Optical Unconscious, by Rosalind E. Krauss
361 pages
FBX 2011 2 Converter
No ratings yet
FBX 2011 2 Converter
32 pages
Cad Cam Lab Manual
100% (1)
Cad Cam Lab Manual
75 pages
DXF Reference
No ratings yet
DXF Reference
306 pages
An Introduction To Photoshop
No ratings yet
An Introduction To Photoshop
8 pages
Magma Trax
No ratings yet
Magma Trax
40 pages
PDF
100% (1)
PDF
424 pages
CAD CAM Unit 2
No ratings yet
CAD CAM Unit 2
47 pages
CADCAM Lab Manual
No ratings yet
CADCAM Lab Manual
127 pages
Reading Material - BIM Tools Matrix 2
No ratings yet
Reading Material - BIM Tools Matrix 2
5 pages
CAD Darshan
No ratings yet
CAD Darshan
196 pages
Delcam - PowerMILL 2017 Getting Started RU - 2016
No ratings yet
Delcam - PowerMILL 2017 Getting Started RU - 2016
94 pages
AOTC AutoCAD Civil 3D 2009 Interchange Design-TOC PDF
No ratings yet
AOTC AutoCAD Civil 3D 2009 Interchange Design-TOC PDF
10 pages
Mold Flow
No ratings yet
Mold Flow
23 pages
CAD/CAM Principles and Applications: CH 4 Geometric Modelling
No ratings yet
CAD/CAM Principles and Applications: CH 4 Geometric Modelling
76 pages
3 - Moldflow Insight 2019 Brochure
No ratings yet
3 - Moldflow Insight 2019 Brochure
4 pages
AUGIWorld MarApr10 LR
No ratings yet
AUGIWorld MarApr10 LR
39 pages
CAD Lecture Notes-RKF
No ratings yet
CAD Lecture Notes-RKF
100 pages
Bridging Moldflow + Ansys
No ratings yet
Bridging Moldflow + Ansys
2 pages
Chapter 13 CNC Programming
100% (1)
Chapter 13 CNC Programming
40 pages
Autodesk FBX QuickTime Help PDF
No ratings yet
Autodesk FBX QuickTime Help PDF
18 pages
CAD Mechanical All Theories
No ratings yet
CAD Mechanical All Theories
165 pages
Presentation - 20885 - UT20885 - Connecting The Dots! How To Integrate BIM Within The Enterprise
No ratings yet
Presentation - 20885 - UT20885 - Connecting The Dots! How To Integrate BIM Within The Enterprise
36 pages
IP 07-Checklist For Simulations&requirements
No ratings yet
IP 07-Checklist For Simulations&requirements
16 pages
FBX Converter
No ratings yet
FBX Converter
36 pages
Analysis of Single Point Cutting Tool
No ratings yet
Analysis of Single Point Cutting Tool
25 pages
Audesk Inventor
No ratings yet
Audesk Inventor
7 pages
CAD CAM CAE Notes PDF
No ratings yet
CAD CAM CAE Notes PDF
101 pages
2CPSC531 Simulation
No ratings yet
2CPSC531 Simulation
28 pages
2015 Produc Key Autocad
100% (1)
2015 Produc Key Autocad
7 pages
Turning Simulation
No ratings yet
Turning Simulation
105 pages
Cad Cam Lab
No ratings yet
Cad Cam Lab
19 pages
Sih 2024 Problem Statements
No ratings yet
Sih 2024 Problem Statements
34 pages
Product Name Product Key
No ratings yet
Product Name Product Key
4 pages
She Hanawa J
No ratings yet
She Hanawa J
67 pages
CAD
No ratings yet
CAD
20 pages
CFD For MEP Exercise 1
No ratings yet
CFD For MEP Exercise 1
19 pages
Manual de Introducción: Autodesk Partmaker 2017
No ratings yet
Manual de Introducción: Autodesk Partmaker 2017
56 pages
Autodesk Feature Codes and Suite Products
No ratings yet
Autodesk Feature Codes and Suite Products
74 pages
Cadcam Geometric Modeling
No ratings yet
Cadcam Geometric Modeling
31 pages
50 Top Design Engineering Software Tools and Apps - Pannam
No ratings yet
50 Top Design Engineering Software Tools and Apps - Pannam
43 pages
Internship Report On CATIA
No ratings yet
Internship Report On CATIA
8 pages
Autodesk Mudbox 2020 Product Keys
No ratings yet
Autodesk Mudbox 2020 Product Keys
9 pages
EZMotion NC English
No ratings yet
EZMotion NC English
54 pages
Mode Frontier
No ratings yet
Mode Frontier
39 pages
Ibrahim Zeid and R. Sivasubramanian - CAD - CAM Theory and Practice (2009, Tata McGraw Hill Education Private Limited) - Libgen - Li-33
No ratings yet
Ibrahim Zeid and R. Sivasubramanian - CAD - CAM Theory and Practice (2009, Tata McGraw Hill Education Private Limited) - Libgen - Li-33
25 pages
2011 04
No ratings yet
2011 04
56 pages
SMD Unit3
No ratings yet
SMD Unit3
29 pages
5905 - FIREPROOF - D-1-3 - Reliability and Effectiveness of Fire Safety Systems
No ratings yet
5905 - FIREPROOF - D-1-3 - Reliability and Effectiveness of Fire Safety Systems
74 pages
Ice M 2 Alias Studio
No ratings yet
Ice M 2 Alias Studio
53 pages
Architecture and Second Digital Turn The Evolution of Digital Tools Within The Design Process
No ratings yet
Architecture and Second Digital Turn The Evolution of Digital Tools Within The Design Process
49 pages
CST Studio Suite - High Frequency Simulation
No ratings yet
CST Studio Suite - High Frequency Simulation
116 pages
ME 6611 Lab-Manual PDF
No ratings yet
ME 6611 Lab-Manual PDF
61 pages
Question Bank-CAD
No ratings yet
Question Bank-CAD
6 pages
3dsmax 2010 Special Effects
No ratings yet
3dsmax 2010 Special Effects
146 pages
Codigos Autodesk 2015
No ratings yet
Codigos Autodesk 2015
3 pages
TABELE Catia Config
No ratings yet
TABELE Catia Config
4 pages
AutoCAD Plant 3D 2023 for Designers, 7th Edition
From Everand
AutoCAD Plant 3D 2023 for Designers, 7th Edition
Prof. Sham Tickoo
No ratings yet
Ilovepdf Merged
No ratings yet
Ilovepdf Merged
503 pages
Slides CAD
No ratings yet
Slides CAD
58 pages
Audo Cad Intro
No ratings yet
Audo Cad Intro
64 pages
CAD Till 26-02-2025
No ratings yet
CAD Till 26-02-2025
103 pages
Role of Computers in Design. 2. Graphic Primitives: Line & Circle Algorithms 3. Geometric Transformations: Translation, Scaling & Rotation
No ratings yet
Role of Computers in Design. 2. Graphic Primitives: Line & Circle Algorithms 3. Geometric Transformations: Translation, Scaling & Rotation
98 pages
Water Colour - Colour Chart: Van Gogh
No ratings yet
Water Colour - Colour Chart: Van Gogh
1 page
Henshin Basic Playset
No ratings yet
Henshin Basic Playset
12 pages
Cgarena Aug12 Magazine
100% (2)
Cgarena Aug12 Magazine
76 pages
Oriflame
No ratings yet
Oriflame
2 pages
High Point Scientific's Basic PixInsight Workflow (2022)
No ratings yet
High Point Scientific's Basic PixInsight Workflow (2022)
3 pages
Greenhouse Effect
No ratings yet
Greenhouse Effect
50 pages
Colorkeyed Spec
No ratings yet
Colorkeyed Spec
150 pages
DataViz 1e Ch03 PowerPoint 2
No ratings yet
DataViz 1e Ch03 PowerPoint 2
40 pages
CLIL Worksheets
No ratings yet
CLIL Worksheets
9 pages
Colors & Musical Correspondences - World Clock
No ratings yet
Colors & Musical Correspondences - World Clock
6 pages
02 Light and Color
No ratings yet
02 Light and Color
50 pages
Including Pete The Cat Worksheets (PDFDrive)
100% (1)
Including Pete The Cat Worksheets (PDFDrive)
114 pages
Zadon Price List Oct2015
100% (1)
Zadon Price List Oct2015
108 pages
Standard Fireworks Price List: Language: English
No ratings yet
Standard Fireworks Price List: Language: English
10 pages
Color Theory 101
No ratings yet
Color Theory 101
15 pages
Mapeh (Mastery)
No ratings yet
Mapeh (Mastery)
3 pages
5 Art Lessons From Bauhaus Master Paul Klee
No ratings yet
5 Art Lessons From Bauhaus Master Paul Klee
15 pages
Customizing MOC To Perfection
No ratings yet
Customizing MOC To Perfection
3 pages
Green C - TC 4005 Green
No ratings yet
Green C - TC 4005 Green
8 pages
Kim, Yu-Jin. (2019, March 16) - The Effect of Color Design On Fragrance Association.
No ratings yet
Kim, Yu-Jin. (2019, March 16) - The Effect of Color Design On Fragrance Association.
13 pages
Pigments For Industrail Application
No ratings yet
Pigments For Industrail Application
41 pages
Bano Trendy
No ratings yet
Bano Trendy
15 pages
4 Colour and Its Measurement in Textiles
100% (1)
4 Colour and Its Measurement in Textiles
43 pages
The Human Aura Swami Panchadasi
100% (2)
The Human Aura Swami Panchadasi
61 pages
DS 700 English
No ratings yet
DS 700 English
39 pages

Note: This service is not intended for secure transactions such as banking, social media, email, or purchasing. Use at your own risk. We assume no liability whatsoever for broken pages.